PROFILE OF BHEL

Bharat Heavy Electrical Limited is the largest Engineering and Manufacturing Enterprise
of its kind in the Public Sector in India. It ranks among the top twelve organizations in
the world, engaged in the manufacture of power generation equipment. The company
provides products, systems and services in the fields of Energy, industry and
transportation.
BHEL has 14 manufacturing plants and 4 power repair divisions. A vital link to this chain
of BHEL manufacturing units is the unit at Ramachandrapuram, Hyderabad.
BHEL, Hyderabad manufactures turbogenerators of rating up to 200 MW for industrial
applications and for power generation to Thermal power stations.
These turbogenerators are supplied together with the turbines and matching
excitation systems, and are used mostly in the Paper, Sugar, Cement, Petrochemical,
Fertilizers, Rayon industries etc. and thermal power stations. The turbogenerators are
based on proven designs and know-how backed by from over three decades of experience
gained by BHEL engineers in this field. Keeping pace with the latest development in
insulation systems to optimize the design, BHEL, Hyderabad has installed the micalastic
(VPI) system of insulation.
BHEL have pleasure in introducing the design features, manufacturing process,
testing facilities and modern methods adopted in the manufacture of turbogenerators to
ensure quality and reliability. It is the only one in ASIA that has the latest type of
insulation system called the VACCUM PRESSURE IMPREGNATION.
The products manufactured in BHEL comprise of:
Turbines
1)Steam Turbines
2) Gas Turbines

Turbine Generators

Switchgears(OCBS&SF6)
Compressors
Heat Exchangers
Boiler Feed Pumps
Pulverisers(Ball&Bowl mill)
Oil-field equipments(on shore oil rigs)
Circuit Breakers
Synchronous Condensers
Motors
Exciters

1) Steam Turbine Generators

2) Gas Turbine Generators
3) Air Cooled Generators

The range of turbo generators manufactured at BHEL, Hyderabad is from 1.5

MW to 200MW. The machine of largest capacity manufactured is 110 MW Air cooled
turbogenerator.
SPECIAL FEATURES OF TURBOGENERATORS DESIGNED BY BHEL
High output to weight to weight ratio.
Thermo-setting class-f epoxy insulation. Both resin rich and micalastic vacuum
impregnation system.
Low loss high grade silicon steel for laminations.
Optimally designed fans on rotor.
Better voltage wave from with less harmonic content.
Low windage loss and low noise.
Static/brushless excitation.
split casing design for a lower manufacturing cycle for a lower manufacturing
cycle for VPI design

INTRODUCTION
Electrical machines are broadly classified into
AC Machines
DC Machines
AC Machines can be categorized as
Rotating Machines
Static Machines
They can be further classified as
Single Phase AC Machines
Three Phase AC Machines: 1.Generator
2. Motor
AC generators can be broadly classified into two types. They are
1. SYNCHRONOUS GENERATOR:
These are the machines in which the speed of the rotor and flux are in synchronism. EX:
Turbo Generator
2. ASYCHRONOUS GENERATOR:
These are the machines in which the flux speed and rotor speed will not be same .EX:
Induction motors.
Inherently all the machines are AC Machines. AC or DC depends on the flow of current
in the external circuit. Electric energy is mainly used for the ease with which it can be
distributed and converted to other desired forms mechanical energy, being the chief
source for Electrical energy is converted to the latter by using the mechanical force to
move a current- carrying conductor in the magnetic field.

The 3-phase Synchronous Generators are the widely used machines for power production
on large scale bases. Hence, the dominant component of power generation is turbo
generator. The word turbo stands for turbine driven. Turbo generators are
synchronous machines, which are usually run by steam turbines or gas turbines.
A 3-Phase synchronous generator basically consists of two parts
1. Stator Stationary part of the generator, used as the armature.
2. Rotor Rotating part of the generator, used to generate the alternating flux.
Synchronous generators can be classified into various types based on the medium used
for generation, they are:
1. Turbo-Generators Steam (or) Gas
2. Hydro Generators
3. Engine Driven Generators
PRINCIPLE GOVERNING THE OPERATION OF A

TURBO GENERATOR
An electrical machine is an electromechanical device, which converts mechanical energy
to electrical energy armor vise versa. An electrical generator is machine; it converts
mechanical energy into electrical energy. An electrical motor is machine, which converts
electrical energy into mechanical energy.
The energy conversion is based on the principle of production of dynamically
induced e.m.f. According to the Faradays laws of electromagnetic induction, whenever
a current carrying conductor cuts magnetic flux , dynamically induced emf is produced in
it .That is , whenever the relative motion between a conductor and a magnet. That is when
a moving coil cuts the magnetic lines or moving magnet field passes through a stationary
coil or a conductor, then an e.m.f induced in the conductor. The induced e.m.f. is directly
proportional to the rate of change of flux and the no of turns. It is given by
E= -N d/ dt
To produce relative motion, either the armature or the magnet has to rotate. In a
DC generator the armature is the rotating part and in an AC generator, it is magnet.
The basic purpose of EMF Generator is the conversion of mechanical to electrical
energy .The energy conversion is based on the principle of production of Dynamically
induced EMF.
Hence basic essential parts required in the production of Production of Power by
the Electrical Generator are
A magnetic field
A Conductor / Coil
Relative motion / mechanical force
In turbo Generator, the magnetic field is rotating part & the coil is stationary.

INTRODUCTION TO TURBO GENERATORS

The generators are primary source of all electrical energy. These Machines are the largest
energy converters found in the world. Depending on the current output i.e DC or AC, the
generators are classified as follows:
AC Generators or Alternators or Turbo generators
DC Generators
The important difference between the above two Generators is that in a D.C. Generator
armature winding is placed on the rotor in order to provide a way of converting
alternating voltage generated in the winding to a direct voltage at the terminals through
the use of a rotating commutator. Since no commutator is required in an AC Generator is
usually more convenient and advantageous to place the field winding on the rotating part.
An alternator is an electrical machine, which converts mechanical into electrical
energy; the electrical energy is in the form of alternating current and voltage. It operates
on the principle of electro magnetic induction. High-speed alternators driven by steam
turbines are called Turbo generators.
Generally the turbines used to drive these turbo generators are of reaction type.
Turbo generators are synchronous machines, which are usually run by steam turbines or
gas turbines. Steam turbine and gas turbine driven generators differ in construction by
location of output terminals on stator frame or type of cooling etc., the basic design of
the generator being the same. For steam turbine generators, the output terminals are
located at bottom of stator frame and for gas turbine generators they are on the top. Gas
turbine generators mostly employ open air cooling and steam turbine generators mostly
employ closed air circuit water cooling. The large capacity turbo generators are
mostly between 1 .5MW to 200MW. 1The main principle on which a generator works
is Faradays Law of Electro Magnetic Induction.
A synchronous generator is a rotating electromagnetic device that converts
mechanical energy into electrical energy by taking the mechanical input from a prime
mover (Gas turbine or Steam turbine) and magnetic energy from excitation.
The standard construction consists of armature winding mounted on a
stationary element called stator and field windings on a rotating element called rotor.
These synchronous machines, with a smooth cylindrical type rotor are used for steam
turbine driven alternators i.e., turbo-generator that run at very high speeds.
The stator supports the armature core, having slots on its inner periphery for
housing the armature conductors .The magnetic poles are excited or magnetized from
direct current supplied by a d.c. source .Brush-less excitation system can be used in
which a 3-phase a.c. exciter and a group of rectifiers supply d.c. to the alternator .
Hence, brushes, slip rings and commutator are eliminated. The rotor is like a flywheel
having alternate N and S poles fixed to its outer rim.
The Speed of all Synchronous machines is intimately connected with the
frequency. The highest possible speed for 50HZ is 3000 rpm, which is suitable for steamturbine drives.
In India, Turbo-generators are being built up to 625 MVA.

The synchronous generator is universally employed for the generation of 3-phase

power at all generating stations. It is a doubly excited AC machine, as its field winding
imports DC power and its armature winding exports AC power.
The generation of dynamically induced e.m.f. is based on Faradays laws of
Electromagnetic induction, which says that the relative motion between the field flux
and the armature winding. In synchronous generator, to attain the relative motion, the
armature is stationary while the field poles are rotating.
Types of synchronous generators

Salient pole generators

Cylindrical or Non-salient generators

Salient pole generators: The salient pole generators have the poles projecting out on
the rotor and it uses concentrated winding. The air gap between the rotor and stator is
non-uniform.
Cylindrical or Non-salient pole generators: The cylindrical generators have the field
winding as a distributed winding housed in rotor slots. The air gap between the rotor
and stator is uniform.
GENERAL ASPECTS OF TURBOGENERATOR
Turbo generators are classified according to their function and the conditions under
which they are supposed to work and deliver the output.
CLASSIFICATION OF SYNCHROUS GENERATORS
Synchronous generators are classified into two main categories based on their design
as:
Smooth cylindrical rotor machines
Salient pole machines.
Generators driven by steam or gas turbines have cylindrical/ round rotors with slots
into which distributed field windings are placed. These round rotor generators are
usually referred to as turbo generators and they usually have 2 or 4 poles. Generators
driven by hydraulic turbines have laminated salient pole rotors with concentrated field
winding and a large number of poles.
CLASSIFICATION BASED ON DRIVE :
GAS TURBINE GENERATORS: Gas turbine can be installed outdoors and without
proper civil structure. They have to operate under extreme temperature 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 from the elements. 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 connection to bus-ducts or through a GAC.
STEAM TURBINE GENERATORS: Small rating steam turbines are designed for high
speeds can 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 and connected to generators directly. Steam turbines are
erected on an elaborate civil foundation in proper power house at an elevation of 6 to 8
meters. The space below the turbine is employed for locating the condenser. 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.

CLASSIFICATION BASED ON SPEED:

The construction of the generator as well as the material used is dependent on
the speed at which the machine is designed to operate. High-speed machines (3000/36000
rpm) are of 2pole design. They employ solid cylindrical rotors 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.
Generators with 4poles run at 1500/1800 rpm and can have rotors built up of
circular laminations stacked and bolted over a steel forging as the 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 and employ radial cooling fans for cooling the machine, which
are fixed on each side of rotor barrel. Salient pole generators are of two types:
a) Laminated pole rotor and b) Solid pole rotors.
In the case of laminated pole rotors, the pole laminations are cut from stampings
and assembled 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 winding, the pole
shoe is fixed to the main pole body by screws. Salient pole generators are fitted with axial
fans for circulating air in the machine for cooling purpose. Fourpole generators are
driven by gas turbine or steam turbines through speed reduction gearboxes.
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 losses. Friction
and windage losses are fixed losses and are dependent on speed. Synchronous machines
run at a constant speed and hence mechanical losses i.e. frictional and windage losses are
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 circuit cooling.
Open circuit air-cooling is mainly employed for Gas turbine generators where
there is scarcity of water. Air is taken in through filters and air ducting and after cooling
of the machine, it is let out into the atmosphere. In the case of closed circuit air cold
machines, the same air is re-circulated inside the machine. Air to water cooler can be

located below, on the side or on the top of machine. Gas turbine generators are mounted
on base-frames. And hence the coolers are mounted on the side.
Generators up to 125 MW capacity of air-cooled. For larger rating machines, hydrogen
cooling is employed. Even larger
machines (~ 500 MW) employ direct cooling of the
stator and rotor windings by circulating water in the hollow conductors. Rest of the
machine is cooled by hydrogen. Hydrogen cooled machines 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. Hydrogen gas system, seal oil system, Carbon dioxide purging system
along with their controls from a very complicated system, requiring continuous
monitoring and maintenance. Hence, air-cooling is increasingly employed up to 300
MVA.
Enclosures are provided for gas turbine generator a) for protection of the machine
from the elements 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.

Generator Nomenclature:
E.g. TARI

1080 - 36 P --- XX --- 15/36 ( 1500/3000 rpm M/C

(Additional Information)
Turbo-generator with Non-salient
pole. (S-salient pole)
Air cooling (H for H2 cooling)
Radial cooling of rotor (I for
Indirect cooling d: for direct axial
Cooling R-direct radial)
Indirect cooling of stator.
Rotor barrel dia. 1080 mm

Active length of stator in dim.

P +11Kv. Class, N=6.6Kv. Class

COMPARISON BETWEEN 2 POLE AND 4 POLE TURBOGENERATORS

2 POLE (3000 RPM)
Sno
CONSTRUCTION OF ROTOR
1.
Solid rotor construction
2.
Ventilation slots

4 POLE (1500 RPM)

Laminated rotor construction

Ventilation ducts between the lamination
packets
3.
Axial entry of air and radial outlet
Axial entry of air and radial outlet
4.
Smaller diameter
Larger diameter compared to 2 pole
5.
Wedges are provided and shorted by Copper damper bars are provided shorted by
retaining rings
copper wire for rotors with dia<1000mm and
shorted by bronze ring for rotors with dia
>1000mm
6.
Retaining ring is compulsory
Retaining ring is not compulsory upto 1000mm
dia.
7.
Large Axial fan
Small Radial fan
CONSTRUCTION OF STATOR
8.
Stator with Roebel bar winding. Stator with multi turn winding. Pulled stator
Individual stator bars made separately
coils.
9.
No restriction on size of stator bars
Maxi puller machine setting imposes limit on
stator bar size
10.
Stator size limited by impregnation tank No such limit due to small ratings
dimensions
PERFORMANCE
11.
Noise level without enclosure ~ 100dBA
Noise is less compared to 2 pole
m/cs(~85dBA)
12.
Higher efficiency
Lower efficiency(due to higher mechanical
losses & rotor copper loss)
13.
High reactance values
Lower reactance values
14.
Rotor temperature limit is 120C
Rotor temperature limit is 130C
PRICE
15.
Cost effective.
Cheaper compared to 2 pole in similar range.
Rotor forging above 930mm dia has to Rotor forgings are locally available.[Haridwar]
be imported [upto 60MW from
Haridwar, >60MW from Germany, Japan]
Retaining rings to be imported from
Airforge, France
Sumitoma, Japan
Crukclockner, Germany

CONSTRUCTIONAL DETAILS OF TURBOGENERATOR

MAIN PARTS OF GENERATOR:

STATOR
Stator frame
Stator End covers
Stator core
Stator bars
Stator windings
Stator core suspension
Output leads / brushings
Temperature measuring devices
Phase connectors
ROTOR
Rotor shaft
Rotor wedges
Rotor coils
Rotor winding
End winding bracings
Retaining rings
Rotor fans
D.C input lead connections
Slip rings
BEARINGS
Based on the principle of operation, the bearings are divided into two main categories.
These are:
Anti friction bearings(rolling element bearings)
Sliding contact bearings
Anti-friction bearings are further divided into:
Ball bearing
Cylindrical roller bearings
Taper roller bearings
Spherical roller bearings
Needle roller bearings
Sliding contacts bearings are further divided into:
Journal Bearing
Thrust Bearing
Journal bearings are further sub divided into
Cylindrical journal bearings
Two-lobe journal bearings(Elliptical bearings)
Three-lobe journal bearings
Pivoted(tiling) pad journal bearings
Thrust bearings are sub divided into

 Flat-land thrust bearings

Taper-land thrust bearings
Pivoted shoe thrust bearings
Spring mounted flexible plate thrust bearings
The bearings used in this type of generator are journal bearings
(one on either side of rotor shaft)
COOLING SYSTEM
There are mainly four types of cooling system depending upon the rating of the generator.
They are,
Air Cooling System(60MW)
Hydrogen Cooling(100MW)
Water Cooling System(500MW)
Water and Hydrogen Cooling System(1000MW)
EXCITATION SYSTEM
Brush Less Excitation System
a) conventional excitation system
b) overhang excitation system
D.C Excitation System(Conventional excitation system with DC exciters)
Static Excitation System
VENTILATION AND PROTECTION SYSTEM
INSULATION
VACCUM PRESSURE IMPREGNATION
EXCITER

BRUSH GEAR
STATOR
STATOR FRAME
The stator frame is manufactured as a two part structure viz. bottom part and top
part. The two parts construction facilities assembly of caged core in the stator frame. The
stator frame is fabricated from the fusion welding quality steel plates. The stator frame is
divided into a no. of compartments ( the cold air and hot air compartments ) for a
effective flow of cooling in the frame .
The frame structure is build up by the welding end plates and a no. of radial ribs
on two feet . The end plates and radial ribs form the walls for different compartments. A
large no of axial ribs are provided between the compartments to provide sufficient
rigidity to the frame to with stand all mechanical forces arising out of different operating
conditions. The stator frame is anchored to the foundation frame, which in turns is
anchored to the concrete foundation with the help of foundation bolts and then grouted.
Stator is of welded steel single piece construction with radial and axial ribs having
adequate strength and rigidity to minimize core vibrations and suitably designed to ensure
efficient cooling .guide bars welded /bolted inside the stator frame over which the core is
assembled . Incase of 1500 RPM generators stator frame is made of two end clamping
plates with axial ribs,welded round the periphery after core assembly.the stator frame for

GT generators are suitably designed for open air as well as CACW cooling . These
frames are suitable for outdoor installations with enclosure designed for the purpose.
Incase of large capacity generators of VPI design,the stator frames are of
horizontal split casing structure to facilitate impregnation of stator and parallel
manufacturing of frame and stator core.
STATOR CORE
The stator core is stacked out of thin electrical sheet steel laminations to minimize
the eddy current losses due to the magnetic flux. Each layer of the core consists of a no of
laminations segments. The laminations are good magnetic properties and a low loss
index. The laminations segments are punched from 0.5-mm thick silicon steel sheet. The
punched laminations are care fully debarred and then coated with the insulation varnish
on both sides.
The core is assembled in between two clamping plates. Then the core is pressed
under a hydraulic press and then clamped in that condition with clamping bolts. Guide
bars are placed at the outer circumference of the core in to the grooves provided in the
lamination segments along the length of the core. All the guide bars except one are
insulated from the core. The guide bars are welded on to be clamping bolts at both ends.
Three nos core cage rings are welded to the guide bars of the core. The clamping
pressure is transmitted to the teeth portion of the laminations by the clamping fingers.
The clamping fingers & clamping bolts are made out of non- magnetic steel to reduce
eddy currents and consequent heating. The clamping arrangement of the core can be seen
in the figure. This arrangement will ensure rigid core. The clamping bolts running
through out the length of the core are insulated from the core and clamping plates. The
core has stepped arrangements at the ends to reduce the leakage flux and consequent
heating of the end zone. The core is divided into a number of packets and the packets are
separated from each other by a ventilation duct. The cooling air which flows through
these ducts in radial direction effectively cools the core.
STATOR COILS/BARS
The stator bars are made out of insulated rectangular electrolytic copper strips. Thin
copper strips are used to minimize the eddy current losses. And thereby eddy current
losses. These insulated copper strips are arranged in two stacks. The stacks are insulated
from each other by a vertical separator. In the slot portion, the strips are transposed 360.
Transposition ensures equal induced E.M.F. In all the strands there by minimizes the
circulating currents. This arrangement is called Roebel bar construction. Then the bar is
consolidated under heat and pressure, in an electric baking press. The bar ends are shaped
to form an involute on a universal forming fixture. Then the bar is applied with high
voltage insulation tape of specified no. of half over lapped layers.
STATOR WINDINGS
The stator winding is double layer 3 phase lap winding . The insulated bars are
carefully placed into slots of the stator core. First the bottom bar is placed in to the slot.
The intermediate filler which separates the top end bottom bars is placed above the
bottom bar. The intermediate filler is made out of hardened glass laminate. Then the top
bar is placed in to the slot and then slot wedge is assembled into the dove tail portion of
along with a top filler.

The overhang portion of the bars are made to rest on insulating winding supports
and firmly secure to them with glass sleeves/ taps. The top and bottom bars are connected
by strip to strip brazing as per the winding scheme. Finally all the 6 ends of the 3 phases
are brought out. The wound stator core is then impregnated in an impregnation tank under
VPI process. The impregnation process involves the following stages:
Placing of the wound core in a tub and placing the tub in impregnation tank.
Evacuation of entrapped air from the wound core by evacuating the impregnation
take.
Then completely immersing the wound core in mixture of epoxy resin+ hardener in
the tub.
Then applying high pressure to the impregnation tank so that the resin ++hardener
mixture penetrates into the voids in the wound core.
Then curing the wound core in a furnace at a specified temperature.
MOUNTING OF CORE IN THE STATOR FRAME
After the stator core is fully impregnated, it will be assembled in the stator
frame .to facilitate the assembly, feet are welded caged core rings. Supporting plates are
welded in the stator frame between radial ribs. Then the core is supported on the
supporting plates provided in the stator frame. This sort of mounting arrangement will
ensure a sufficiently rigid core and at the same time some amount of damping takes place
in the case of core vibrations.

Transposition Arrangement For The Stator Conductor

The stator conductors are transposed by famous roebel transposition method. The
conductor is composed of two stacks of thin rectangular strips. Each strip is given two
links edge wise to obtain 360 transposition. The position of the bends is so arranged that
it is possible to accommodate all the strips in the slot length of the machine or in other
words pitch for transposition is obtained by dividing the slot length by the number of
strips. The roebel transposition is done to ensure that all the strips occupy equal length
under similar conditionsof the flux where by differential induction between the top and
bottom most strips are eliminated. Such an arrangement will eliminate the losses in the
conductor due to circulating current, which would have resulted in case of untransposed
conductor.

Stator End Covers

The end covers are the castings of the aluminum alloy and are bolted to the side plates
of the stator frame. The inlet passage is specially designed with built in guide vanes,
which ensure uniform distribution of the air to the fan. Air ceiling is provided around
the shaft and at the parting plane of the top and bottom parts of the end covers so that
suction of oil vapour from the bearings does not take place.

Enclosure
The enclosure consists of the inner and outer components. The inner components
comprises of the winding covers, which from an angular enclosure of top and bottom
parts and is designed as required for particular degree of protection, as indicated in the
dimension drawing or in the Technical data. The ventilating circuit is of the doubleended symmetrical arrangement.

Electrical Connections of Bars and Phase Connection

Brazing makes electrical connection of Bars: Electrical connection between the top
and bottom bars, one top bar being brazed to the associated bottom bar. The coil

connections are wrapper depends on the machine voltage. After tapping, an insulating
varnish is applied.

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 soldered type. The phase connectors are wrapped with resin rich mica type, which
contain synthetic resin having very good penetration properties. The phase connectors
are then cured at a certain temperature, with the shrinking tapes contracting so that a
void free insulation is obtained.

Output leads
The beginning and ends of three phase windings are solidly bolted to the output leads
with flexible. The output leads consist of flat copper sections with mica insulation. To
prevent eddy-current losses and inadmissible temperature rises: the output leads are
brought put.
Temperature measuring devices
RTDs & Fire Detectors
In stator winding, between bottom bar and top bar
In stator core
In hot and cold air chambers
In bearing shell
Fire detectors mounted on both sides of the stator core to detect fire inside the
generator.

ROTOR
Rotor Shaft
The rotor of turbo generator is single piece alloy steel forging, which is forged
from a vacuum degassed steel casting. The rotor consists of an electrically active portion
(BARREL PORTION) and two shaft ends. An integrally forged coupling flange is
provided to connect the rotor to turbine rotor.
The operation requirements of the rotor are high mechanical strength and good
magnetic properties as well as freedom from defects. Mechanical, magnetic and NDT
tests are carried out on the forging to ensured the quality requirements.
Approximately 60 of the rotor barrel circumference is provided with longitudinal
slots, which house the field winding. The unslotted portion acts as two poles, which are
180 (degree), a part.
ROTOR COILS
The rotor coils are manufactured from 0.1% silver alloyed copper strips.
Individual conductor is bent to obtained half turns. Rectangular cooling slots are
punched on the conductor at regular intervals for the flow of cooling air. After these half
turns are inserted in to the rotor slots, these are braced together to from full turns. All the
series connected turn of one pair of slots constitute one coil. Then different coils of rotor
winding are connected in series such that one north and one south obtained.
The inter-turns insulation between the turns is made of glass fiber laminate. The
coils are insulated from the slot walls with L-shaped strips of glass fiber laminate with
nomex filler. A thick glass fiber laminate is inserted above the top most turn. The total

slot contents are then tightly secured by driving a wedge in to the dove tail portion of the
rotor slot.
ROTOR SLOT WEDGES
To protect the winding against the effective of centrifugal force, the coils in the
rotor slots are firmly secure with wedges. The material used for rotor wedges shall have
good mechanical strength non-magnetic property and good electrical conductivity. To
achieve the above properties, cupro-nickel alloy drawn profiles are used as rotor wedges.
These wedges extend below the shrink fit seating surface of the retaining rings. The
retaining rings, along with the rotor wedges will acts as damper windings.
ROTOR END WINDINGS BRACING
The spaces between different rotor coils in the end-winding region are fitted with
insulating bracers. These insulating braces prevent the deformation / movement of
individual coils and ensure the end winding as a single entity. These braces will also
guide the airflow so that intensity cooling of end winding takes place.
The shrunk on hub at the free end of the retaining ring, serves to maintain the
circularity of retaining ring due to un-symmetrical loading by rotor end winding. A snap
ring is provided for additional protection against axial displacement of retaining ring.
Non-magnetic, cold worked high strength alloy steel forging are used for retaining rings.
Non-magnetic material ensures reduced stray losses. Magnetic permeability (Nonmagnetic property)
And NDT tests are conducted on the retaining ring forging to ensure the quality of
the forging.
The shrink fit surface of retaining is coated with nickel + aluminum + silver to
ensure low contact resistance between wedges and retaining surface. The retaining ring
with their sink fit areas acts as short circuit rings of the damper winding system (rotor
wedges acts as damper bars).

ROTOR FANS
Two axial flow fans located on the shaft at both ends circulate generator-cooling
air. The fan consists of aluminum alloy forge blades with threaded roots. The blades can
be screwed on to the rotor in which threaded holes are already provided. Threaded root
fastening permits the blade angle adjustment. Each blade is secured at its root by locking
with a grub screw.

Cooling of Rotor Windings

Each turn is subdivided into four parallel cooling zones. One cooling zone
includes the slot from the center to the end of the rotor body, while another covers half
the end winding to the center of the rotor body. The cooling air for the slot portion is a
limited into the slot bottom ducts below the rotor winding. The hot gas at the end of
the rotor body is then discharged into the air gap between the rotor body and stator
core through the radial openings in the conductors and in the rotor slot wedges. The
cooling air for the end windings is drawn from below the rotor-retaining ring. It rises
radically along the individual coils and is then discharged into the air gap.

Rotor Retaining Rings

The rotor retaining rings with stand the centrifugal forces due to the end
windings one end of each ring is shrunk on the rotor body, while the other end of the

ring overhangs the end winding without contact on the shaft. The shrunk on the hub at
the free end of the retaining serves to reinforce the retaining ring and secures the end
winding in the axial director at the same time. The shrink seat of the retaining ring is
silver plated, ensuring a low contact resistance for the induced current. To reduce the
stray losses and have high strength, the rings are made of non-magnetic core worked
materials.
Retaining rings firmly secure the rotor windings from the effect of centrifugal
forces during operation one end of the retaining ring is shrunk on to the rotor body, while
the other end of the retaining ring over hangs the end winding without making any
contact with shaft. This ensures an un-obstructed shaft deflection.

Slip Rings
These are made of forged steel and shrunk on either side of the rotor between the end
cover and the bearing. The mica splitting is used to insulate the slip rings from the
rotor body. The excitation to the rotor winding is taken from these slip rings. The
connection leads are suitably insulated and taken through slots milled on the surface of
the rotor. Wedges are provided to keep the leads in position. A helical groove is
machined on the outer surface of the slip rings to have better dissipation of heat, thus
minimizing the brush wear.
Slip rings are provided for turbo generators with conventional DC rotating or static
excitation system. These are of alloy steel forgings shrunk fitted on the rotor shaft and are
insulated from the shaft. for the rotor earth fault protection, the rotor is provided with an
additional brush, which is fixed to the bearing on the drive side and is in contact with
rotor shaft during operation. Rotors are dynamically balanced to eliminate unbalance and
vibration in operation. Over speed test at 120 percent of rated speed for 2 minutes is
carried out to ensure mechanical soundness of the rotors.
Rotor Balancing
The rotor is balanced with the help of sophisticated balancing machine. The balancing
weights are provided in the hubs under retaining rings and in the fans. The rotor is
dynamically balanced and subjected to an over speed of 20% for 2min.

Field Connections
The field connections provide the electrical connection between the rotor winding and
the exciter.

Terminal Lugs
Consists of a copper conductor of rectangular cross-section. One end of the terminal
lug is brazed to the rotor winding, while the other end is screwed to the radial bolt.

Radial Bolt
The field current lead located in the shaft bore is connected to the terminal lug through
a radial bolt. The radial bolt is made from steel and screwed into the field current lead
into the shaft bore.

BEARINGS
The turbogenerators are provided with pressure lubricated self aligning
ellipticaltype bearings to ensure higher mechanical stability and reduced vibration in
operation .The bearings are either end shield mounted or pedestal type.suitable
temperature element devices are mounted in the bearings to monitor bearing metal
temperature in operation.

The rotor shaft is supported in sleeve bearing having forced oil lubrication. The
bearings are located in bearing pedestals. The oil required for bearing lubrication and
cooling is obtained from the turbine oil supply system and supplied to the lubricating gap
via the bore in the bearing pedestals and via grooves in the lower half of bearing shells
The lower bearing shell with its self alloying outer surface rest on the bearing
pedestals. The E.S. bearing pedestal is insulated to prevent the flow of shaft currents and
to provide for insulation oft the generator bearing from ground. The pipes flanges to the
bearing pedestals are like wise insulated from the bearing housings.
A tangential stopper is provided at the bearing shell parting plane to prevent the
bearing shell from turning in the pedestal.
The inner surface of the cast bearing sleeve body is provided with spiral a dove
tail groove which firmly holds the Babbitt liner to the bearing sleeve body.
The lower bearing sleeve has grooves to admit the lube oil on to the bearing
surface. The upper sleeve consists of a wide over flow groove through which the oil is
distributed over the shaft journals and fed to the lubricating gap. The oil is drained
laterally from the lubricating gap, caught by baffles, collected in the bearing pedestals
and returned to the turbine oil tank.
All the generator bearings are provided with a hydraulic shaft lift oil system to
reduce bearing friction during start-up and turning gear operation. High pressure oil
forced between the bearing surface and the shaft journal, lifting the rotor shaft to allow
the formation of a lubricating oil film.
The bearing temperature is monitored with RTDs located approximately in the
plane of maximum oil film pressure. The RTDs screwed in position on one side of the
lower bearing sleeve from out side with the detector extending up to the Babbitt liner.
BEARING INSULATION
To prevent damage to the journals due to shaft currents, bearings and oil pipings on either
side of the non-drive end bearings are insulated from the foundation frame. For
facilitating and monitoring the healthiness of bearing insulation, split insulation is
provided.

VENTILATION AND PROTECTION SYSTEM

Ventilation and Cooling
Turbogenerators are designed with the following ventilation systems:
Closed circuit air cooling with water/air coolers mounted in the pit.
Closed circuit hydrogen cooling with water/hydrogen coolers mounted axially on the
stator frame.
The fan designusually consists of 2 axial fans either of cast aluminium with integral
fan blades or forged and machined aluminium alloy blades screwed to the rotor.
In the case of 1500 RPM generators, fabricated radial fans are provided.

Ventilation Arrangement
The turbo generator is cooled by air circulated by means of two axial fans. Air coolers
cool the air after circulation. The air is drawn through suction ducts by axial fans
mounted on either side of the rotor. The warm air flows out through the exhaust at the
bottom of the stator frame.

Space heaters

These heaters are used to circulate warm air inside the turbo generator and during
outages to prevent condensation of the moisture inside the machine. They are of strip
type and robust design. The heating elements are enclosed in a steel sheet with
specific rating of 15W per sq. inch of the surface. They are so designed that they may
be fixed in the suction ducts of the turbo generator. The heaters are completely
covered in order to prevent the accidental contact with the heat units.

Resistance Temperature Detectors

The resistance temperature detectors are made up of Platinum resistance elements. The
detectors are placed in a groove cut in a rectangular glass laminate and embedded in
different positions like stator teeth, stator core, and slots. There are 12 active and three
spare elements distributed in different locations in 3 different planes, 5active plus 3
spare elements are placed in stator slots, 4 active are placed in stator core, 3 are placed
in teeth to measure the hot and the cold air temperatures. The resistance thermometers
are fixed in the exhaust hood of the stator frame and the end covers. The leads from
these resistance thermometers are brought out and connected to the terminal board.
The leads coming from the spare elements are brought up to the terminal board and
left inside the machine. These resistance temperature detectors operate on the principle
that the resistance of the elements will change depending on the temperature
coefficient of the element. The change in resistance can be accurately measured in a
bridge circuit. A graph is drawn showing the variation of resistance with temperature,
which is used to know the temperature rise under different operating conditions of the
turbo generator.

Fire Detectors
For the protection of turbo generator against any possible fire hazards 12 fire detectors
relays are provided on either side of the stator winding. These relays have a set of
normally open contacts. The set of contacts will close when the temperature
surrounding the first relay exceeds 80deg Celsius. The other relay set of contacts close
when the temperature exceeds 1000. These contacts are wired up to the terminal board
provide on the stator frame for the resistance temperature detectors. Both the sets of
contacts are used for automatic fire alarm shutting down of the turbo generator system
and for the release of CO2 gas from the Carbon dioxide system.

PROTECTION SYSTEM
Generator are provide with static or microprocessor based protections based on
customer requirements. The protections normally provided are:
Differential protection

Overcurrent protection
Overvoltage protection
Loss of excitation protection
Under frequency protection
Negative sequence current protection
Reverse power /Low forward power protection
Rotor earth fault protection
Stator earth fault protection
Under frequency protection

These protections are supplemented with additional protections like pole slipping
protection and stator earth fault protection covering 100 percent winding.

COOLING SYSTEM
Cooling is one of the basic requirement of any generator. The effective working of
generator considerably depends on the cooling system. The insulation used and cooling
employed are inter-related.
The various losses in the generator are broadly classified as below.
1. Iron losses / Core losses / Magnetic losses / Constant losses
2. Hysterisis Losses
3. Eddy current losses
4. Copper losses / I^2*R losses / Winding losses
5. Mechanical losses /Friction /Windage losses.
These losses in the generator dissipates as the heat, it raises the temperature of the
generator .Due to the high temperature,the insulation will be affected greatly.So
the heat developed should be cooled to avoid excessive temperature raise. So the
class of insulation used depends mainly on the cooling system installed.
various methods of cooling
Air cooling(Indirect forced): upto25MW
Air cooling (Direct forced): upto150 MW
Hydrogen cooling(Direct forced): upto250MW
Water cooling: upto 500MW
Hydrogen with Water cooling: upto1000MW
Types in air cooling:
Open air cooling for Gas turbine generators.
Closed circuit air cooling with air cooled by open circuit water (CACW)
Closed circuit air cooling with air cooled by closed circuit water with
cooling water module.
COMPARISION OF HYDROGEN AND AIR COOLED TURBOGENERATOR
Hydrogen has more specific heat.
Hydrogen is lighter hence more compressible and produce less
windage loss.
Hydrogen is non supporter of combustion.
Hydrogen is explosion prone .
Running cost is more.

AIR

Vs

HYDROGEN

COOLED:
ITEM

AIR

HYDROGEN

Current Densities

Lower

Higher

Flux Densities

Lower

Higher

Losses

Higher

Lower

Lower

Higher

Lower

Higher

Heat transfer

Lower

Higher

Kg/KVA

Higher

Lower

Lower

Higher

Nill

Exits

Lower

Higher

Auxiliaries

Nill

Exits

Maintainence Cost

Lower

Higher

Efficiency
Excitation
requirement

Cost/KVA
Operational
Hazard
Time of Starting/
Stopping

Hydrogen cooling has the following advantages over Air cooling

1.Hydrogen has 7 times more heat dissipating capacity.
2.Higher specific heat.
3.Since Hydrogen is 1/14th of air weight. It has higher compressibility.
4.It does not support combustion.
Disadvantages
1. It is an explosive when mixes with oxygen.
2. Cost of running is higher.
3. Higher capacity generators need better cooling system.
Turbogenerator is provided with closed circuit air-cooling system. The heat losses arising
in the generator interior are dissipated to the secondary coolant (cooling water)through
air.
DIRECT COOLING
Direct cooling of the rotor essentiality eliminates hot spot and differential
temperatures between adjacent components which could results in mechanical stresses,
particularly to the copper conductors, insulation and rotor body. Indirect air-cooling is
used for the stator winding.
AIR-COOLING CIRCUIT

The cooling air is circulated in generator interior in closed by two axial flow fans
arranged on the rotor shaft. Cold air is drawn by the fans from the cooler compartments.
The cooling airflow is divided into three flow paths after each fan.AIR COOLER
The air cooler is a shell and tube type heat exchanger, which cools the air in the
generator. The heat removed from the cooling air is dissipated through the cooling water.
The cooling water flows through the tubes, while cooling air passes around the finned
tubes.
Six identical cooler elements are provided in an air cooler unit, which is mounted, by the
side of the generator. Out of the six elements five elements are sufficient for operation
and one element is spare. The spare element is closed on airside with a FLAP. Any
element can be made spare by shifting the FLAP to that element.
Each element is provided with a gate valve in the water inlet line and one globe
valve in the water outlet line (Hot water line).
The required cooling water flow depends on the generator output and is adjusted by
regulating the valve in the water outlet line. Controlling the cooling water flow on the
outlet side ensures an uninterrupted water flow through the cooler elements.
The air cooler unit is provided with a make up air filter. The air filter provides a low
resistance path to atmosphere air, which enters to make for any leaked air. The make up
air is cleaned by the air filter before it enters the generator cooling air circuit.
SYNCHRONOUS GENERATORS- LOSSES AND COOLING
All electrical machines produce heat owing to various losses generated inside the
machine (like the I2R losses of stator copper winding). These losses are categorized as
fixed and variable. Friction and windage losses, which include hysterisis and eddy
current losses, are all considered to be fixed losses while the rotor copper losses, are
treated as variable losses. Friction and windage losses are dependent upon speed and
as synchronous machines run at constant speed, these losses are constant. As the
magnetic flux passes through stator laminations, hysterisis and eddy current losses
result in and are dependent on the magnitude of flux. As long as machine is delivering
power at a constant voltage, which is normal case, these losses in the laminations are
fixed. The stator copper losses and rotor copper losses vary in square proportion to the
stator and rotor currents respectively. These currents vary in accordance with the load
and thus in turn the losses also vary and hence termed as variable losses.
Core / Magnetic losses(constant with voltage)
Copper / winding losses(variable with load)
Bearing friction & windage losses(constant with speed)
As the synchronous machine has to deliver the output continuously, the heat
generated inside the machine has also to be taken away at the same rate so that the
machine can operate at a stable temperature continuously; ensuring a longer life for
the insulation system which in turn ensures a longer life of operation of the generator
itself.
Generally Upto 125 MVA air-cooling is employed.
Hydrogen cooling is employed in the machines i.e., above 125MVA; as it is
more efficient compared to air-cooling.
For still higher ratings like above 500MVA, Water-cooling is employed.
Air cooled generators are the simplest in design and either open air ventilating
cooling system or a close air close water circuit (CACW) cooling can be employed.
Open circuit air-cooling depends on the ambient temperature unlike the CACW

cooling and this open air-cooling is employed for the Gas turbine generators where
there is scarcity of water.

INSULATION
In electrical machines insulation is most important requirements to sustain high voltages
and basically insulation is the heart for electrical machines. Any insulation should have
high dielectric strength , good thermal conductivity, and high mechanical strength.
Insulation is the property , which has enormous resistance to the flow of current.it is
basically the forbidden gap between valence and conduction bands for these insulation is
very high.The property of insulation material is non conductive to electricity and
conductive for heat.
The high voltage insulation is provided, with thermosetting system. The
high voltage insulation is particularly voided free and characterized by excellent
electrical, mechanical and thermal properties. To prevent corona discharges between the
insulation and the slot wall, a final coat of conducting varnish is applied to the surface of
all bars within the slot range. All bars are additionally provided with an end corona
protection to control the electrify field at the transition from the slot to the end winding
portion and to prevent the formation of creep age sparks.
Flexible hardened glass laminates with suitable resins are used as interturn
insulation. The insulation is thermally consolidated to form a compactness capable of
withstanding mechanical forces in operation generators of 1500RPM, the rotor, after
winding is subjected to impregnation in epoxy resin followed by curing which results in
good bonding between layers and a high compact insulation. For the rotors designed with
four-flute system of ventilation, insulation rings are mounted below the overhang
winding and locked by means of special springs for effective ventilation.
INSULATING MATERIALS
Insulation is provided between the core and the windings ,and also between the
conductors.insulating materials are wound around the conductors .some of the insulating
materials used are :
1.Polyster Glass Tape
2.Resin Rich
3.Resin Poor
4.Polyester Tape
5.Diamond Coil
6.Fine Mica
7.Nomex
PROPERTIES OF INSULATING MATERIALS
1. The basic function is to provide isolation of live wire to earth.
2. It should be a good conductor of heat and bad conductor of electricity .
3.it should withstand the design mechanical stress .
4.it should have good chemical and thermal resistivity and environmental resistance
(chemically inert).
In order to achieve good insulation properties, the following process is followed:

1.Thermoplastic process of insulation

2. Thermosetting process of insulation.
Thermosetting process of insulation is basically of two types. They are
a) Thermo Reactive Resin Rich System
b) Micalistic-VPI resin poor system
a)Thermo Reactive Resin Rich System:
The system is class F Thermo reactive epoxy mica paper employing stage B
impregnated epoxy mica resin rich tape, which is consolidated under heat and pressure.
In this system, stage B epoxy mica tape material has limited shelf life and requires
controlled condition of tower temperature storage.
This system provides the usage of resin rich polyester backed epoxy
mica folium on straight portion and resin rich polyester backed epoxy mica paper tape on
overhang with a final layer of polyester shrink tape. The system is highly productive
during coil manufacture and housing.
The wound stators are totally impregnated in unsaturated polyester resin through
rolling technique. For brazing of coils, usage of woven polyester felt around molded
casting is in common, which provides bond between coils after impregnation. Insulation
thickness in mm adopted for main insulation is much less in comparison to Resiflex
insulation system.
b) Micalistic-VPI Resin Poor System:
Micalistic class F insulation system is based on resin poor technology. This consists of
high strength mica and thermo-setting solvent-less epoxy resin with vacuum
impregnation. The system employing elaborate manufacturing facility gives higher value
of production and more consistent quality because of lesser manual operation and more
automation.
Resin poor micalistic system is adopted for large range AC insulation and synchronous
machines. These are designed to meet specific customer requirement hence are unique in
nature to each other. The main insulation consists of resin poor epoxy mica paper tape all
over the coil periphery with varying number of layers on straight and overhang portions.
The wound rotors are impregnated under vacuum to avoid free monolithic thickness are
slightly higher than those used for resin rich Micalistic insulation system. This system
satisfies class F requirements but being thermally utilized to class B temperature only,
therefore there is a thermal reserve, which results in
1) Prolonged life
2) Increased reliability
3) Capacity for occasional overload
The comparison between resin rich and resin poor is as follows

Resin poor

Resin rich

1) Epoxy resin content is about 8%

2) This method follows thermo setting
process
3) Addition of resin from outside is needed
4) Reduction in time cycle for this process

1) Epoxy resin content is about 40%

2) This method follows thermo setting
process
3) Further addition of resin is not required
4) It is very long process and time
consuming
5) Repairing work is easy.
6) Overall cost is more

5) Repairing is very difficult.

6) Overall cost is less in comparison

7) No test is carried out here on bars

7) Tests are being carried out while

processing such dielectric test and high
voltage(HV) test.

Committees and organizations that set standards have grouped insulators into five classes,
depending upon their ability to withstand heat. These classes correspond to the maximum
temperature levels of: 105c, 130c, 155c, 180c, and 220c (formerly represented by the
letters A, B, F, H and R). This thermal classification (Table 6B) is a cornerstone in the
design and manufacture of electrical apparatus.
CLASSES OF INSULATION SYSTEMS
Class
Illustrative examples and definitions
105c
Materials or combinations of materials such as cotton, silk, and paper when
A
suitably impregnated or coated or when immersed in a dielectric liquid
such as oil. Other materials or combination of materials may be included in
this class if by experience or accepted tests they can be shown to have
comparable thermal life at 105c.
130c
Materials or combinations of materials such as mica, glass fiber, asbestos,
B
etc., with suitable bonding substances. Other materials or combination of
materials may be included in this class if by experience or accepted tests
they can be shown to have comparable thermal life at 130c.
155c
F

Materials or combinations of materials such as mica, glass fiber, asbestos,

etc., with suitable bonding substances. Other materials or combination of
materials may be included in this class if by experience or accepted tests
they can be shown to have comparable life at 155c.

180c
H

Materials or combinations of materials such as silicon elastomer, mica,

glass fiber, asbestos, etc., with suitable bonding substances such as
appropriate silicon resins. Other materials or combinations of materials
may be included in this class of by experience or accepted tests they can be
shown to have the comparable life at 180c.
Materials or combinations of materials which by experience or accepted
tests can be shown to have the required thermal life at 200c.
Materials or combinations of materials which by experience or accepted
tests can be shown to have the required thermal life at 220c.
Materials or combinations of materials which by experience or accepted
tests can be shown to have the required thermal life at 240c.
Materials consisting entirely of mica, porcelain, glass, quartz, and similar
inorganic materials. Other they can be shown to have the required thermal
life at temperatures above 240c.

200c
N
220c
R
240c
S
220c
C

The above insulation classes indicate a normal life expectancy of 20 000h to 40 000h at
the stated temperature. This implies that electrical equipment insulated with a class A
insulation system would probably last for 2 to 5 years if operated continuously at 105c.
Note that this classification assumes that the insulation system is not in contact with
corrosive, humid, or dusty atmospheres.
For a complete explanation of insulation classes, insulation systems, and temperature
indices, see IEEE Std 1-1969 and Underwriters Laboratories publication on insulation
systems UL 1446, 1978.

EXCITER
Features
The exciter consists of
Rectifier wheels
Three-phase main exciter
Three-phase pilot exciter
The three-phase pilot exciter has a revolving field with permanent-magnet poles. The
three-phase ac is fed to the field of the revolving-armature main exciter via a
stationary regulator and rectifier unit. The three-phase ac induced in the rotor of the
main exciter is rectified by the rotating rectifier bridge and fed to the field winding of
the generator rotor through the dc lead in the rotor shaft. A common shaft carrier the
rectifier wheels, the rotor of the main exciter and the permanent magnet rotor of the
pilot exciter. The generator and exciter rotors are thus supported on a total of three
bearings. Mechanical coupling of the two-shaft assemblys results in coupling of the
dc leads in the central shaft bore through the multi contract electrical contact system.

Rectifier wheels
The main components of the rectifier wheels are the silicon diodes, which are
arranged in the rectifier wheels in a three-phase bridge circuit. A plate spring assembly
produces the contact pressure for the silicon water of the diodes. One diode each is
mounted in each light metal heat sinks and then connected in parallel. Associated with
each diode is a fuse, which serves to switch off the diode from the circuit if it fails.
Each arm of the diode bridge is provided with one RC block. The three-phase
connection between the armature and diodes is obtained through copper conductors
arranged on the shaft circumference between the rectifier wheels and the main exciter.
One conductor is provided for each arm of the diode bridge. The conductors originate
at a bus ring system of the main exciter.

Three-phase pilot exciter

It has a frame, which accommodates the laminated core with the three-phase winding.
The rotor consists of a hub with mounted poles. Each pole consists of separate
magnets, which are housed in non-magnetic metallic enclosure.

Three-phase Main Exciter

It is a revolving armature unit, the frame poles with the field and the damper winding.
The field winding is arranged on the laminated magnetic poles. The rotor consists of
stacked laminations, which are compressed through bolts over compression rings the
three-phase winding is inserted in the slots of the laminated rotor. The winding
conductors are transposed with in the core length and the end turns of the winding are

secured with the steel brands. The winding ends are run at bus ring system to which
the three-phase leads leading to the rectifier wheels are also connected. After full
impregnation with epoxy resin and curing, the complete rotor is shrunk onto the shaft.
AC EXCITERS
The ac exciter are a specially designed induction type alternator with no winding on its
rotor. The armature &field winding are accommodator in the stator .the 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 field winding of generator &series field winding
of ac exciter through a field breaker .the magnetizing &demagnetizing field windings of
ac exciter are controlled by AVR. The power required by AVR is provided by a
permanent magnet generator.
Since there is field winding on the rotor of AC exciter, the ac exciter
proved to be very reliable in operation. Though this system eliminates all problems
associated with commutator, it is not free from problems attributable to slip rings &its
brush gear .the brush less excitation system provided the answer for all these problems.
Former practice now almost absolute is due to the following disadvantages:
1. A no. of exciters operating in parallel supply the excitation bus
2. The layout of station will be much complicated
3. The excitation of the failed ac generator AC generator is to be supplied
by the remaining ac generators

EXCITATION SYSTEM
When a generator operates, alone the excitation is controlled to maintain the steady state
voltage within the necessary limits and to prevent unacceptable variations of voltage
when large and sudden changes of load occurs. Generators running in parallel may need
additional control signals to share the total reactive load correctly between them. In
interconnected system control of steady & transient stability is a vital duty .The basic
function of the excitation system is to provide the required dc field currents to magnetize
the rotor of turbine generator .the exciter is generally a four pole or a six pole revolving
field ac generator, which operates in saturated path of its characteristic, to maintain
linearity between generator slip rings voltage &controlled excitation of main exciter.
Generators can be supplied with any of the following excitation systems
1)Brush less excitation system
Conventional excitation system
Over hang excitation system
2)Static excitation system
3)Conventional excitation system with DC exciters(Dc excitation system)
Important characteristics of Excitation System are:
i) Quick response of the exciter to the AVR. The response is measured in terms of
nominal exciter response.
ii) High ceiling voltage.
Nominal exciter response = slope of straight line.
Nominal collector ring voltage.
Main Features
An excitation system with rotating rectifiers consists of an auxiliary exciter with rotating
permanent poles and a main A.C.exciter with a stationary magnet system and a rotating 3
phase A.C. winding to which silicon rectifiers are connected.

The rotors of these two machines are coupled direct to the shaft of the main generator. As
in the case of direct coupled D.C.exciters, this makes the excitation circuit independent
of any external auxiliary system.
The main advantages of this excitation arrangement are :
No commutators
No slip-rings
No carbon brushes
No pollution by carbon dust
Minimum maintenance
High reliability.
Selection of Excitation Voltage and Current:
The voltage &current rating of the excitation system is selected in order to give the
following:
1. To give field winding conductors that is mechanically robust in small machines & too
massive in large machines.
2. Suitable the ratings of available diodes or Thyristor.
3. To give convenient design of exciter &of slip rings where these are used.
4. At no load or with leading pf, control of the excitation current is needed to come
down to about 1/3 of the value for rated load.
The excitation system must respond to applied signals quickly enough to have the desired
effect on the generator flux It duties can be broadly classified as

To control the generator voltage accurately as slow changes of power and reactive
loading occur.

To limit the fluctuations of voltage when loads are suddenly imposed or removed.

To maintain steady state stability &transient stability

TYPES OF EXCITATION SYSTEMS
a) Brush less excitation system
This system comprises shaft driven AC exciter with rotating diodes,
permanent magnet generator and AVR .This system is highly reliable with least
maintenance and is ideally suitable for gas turbine driven generators.
In this method the collector brush gear, the commutator brush used
conventional excitation systems are eliminated. brushless ac generator has its excitation
power supplied to the field windings from the rectified output of a direct coupled
revolving armature of ac exciter. This requires the rectifier is to be mounted in hub, which
rotates with shaft & necessities the omission of main field suppression equipment this
inivation introduces a much shorter exciter time delay due to a fact that a conventional
DC exciter is replaced by a high frequency. The smaller time delays the system easier to
stabilize &improve the overall system response.
B.L. Exciters
No brushes
A rectifier wheel converts the ac output of the BLE armature to dc.
They are either coupled or overhanged mounted.
Constructional Features
It is also another generator
The field is on the stator unlike the turbogenerator.
The armature is on the rotor.

 All the brushless exciters have inbuilt / separately mounted PMGS.

Advantages of Brushless Excitation Systems
1. High reliability
2. Minimum maintenance
3. Immunity from environment
4. No power cabling
Disadvantages
1.No generator field breakers
2. No direct field currents &temperature measurements
3. Presence of additional rotating machine in the system

Brush less Exciters Nomenclature:

E A R 50 / 15 - 30 / 8 - 3
Exciter
Air-cooled
Rotating Rectifier Diode Wheel
Diameter
Length
rpm
No. of poles
Number of diodes in a bridge arm
b) Static excitation system
This system consists of rectifier transformer, Thyristor converters, and
field breaker and AVR . this system of ideally suitable where fast response is called
for. The system is flexible in operation and needs very little maintenance.
It consists of:
1. A SCR bridge cubicle
2. A field breaker
3. A field flashing ckt
4. An AVR
c) Conventional excitation system with DC exciters (DC excitation system)
The exciter was a dc generator coupled to the shaft of the synchronous

machine, feeding its output to the main field through slip rings.
Conventional D.C Excitation Systems with a D.C. exciter enjoyed an
unchallenged position till recently was adopted universally for all alternators. With the
growth in unit size of large capacity D.C. exciters capacity became necessary. Due to
problems in communication it became inevitable to design of large capacity D.C.
exciters at low speeds leading to increase in the systems. Moreover, the D.C.
excitation suffered from problems like power cabling, problems associated with
commutator and brush gear and maintenance.With the advent of high power solid state
semiconductor devices, significant strides were made in the development of new
excitation systems and thus in order to liquidate the communication and brush gear
problems of the D.C, the A.C exciters were introduced.
Advantages of Conventional Excitation System :
1. Availability of excitation power even if the power supply or AVR failures
2. Economical
3. Good exciter response
4. Measurement of field is possible.
Disadvantages
1. Maintenance of brushes.
2. Commutator problem
3. Extensive power cabling
EXCITATION SYSTEM WITH DC ROTATING EXCITER
In these excitation systems, dc exciter is connected to the field winding of turbo generator
through a field breaker. Current through exciter field winding is controlled by an
automatic voltage regulator depending upon generator voltage &load parameters. the
parameter magnet generator provides ac power supplies &hence the system is very
reliable .this winding provides about 70c of excitation power is provided by the second
winding is connected to AVR.
Usually up to500kw capacity, exciter are directly driven by the generator rotor
@3000rpm with the growth in unit size of generator it became necessary to design large
capacity dc exciter. Due to problems in commutation, it became inevitable to design large
capacity dc exciter @low speeds.
A.C excitation:
Systems are classified into two types as:
High Frequency Excitation System was developed. At present this is the system,
which is widely used owing to its reliability, good transient performance and least
maintenance. The system also doesnt suffer from the problems of communication,
brush gear and power cabling. However, the main disadvantage of the system is that
the rotor is not accessible and thus fast de-excitation, in case of any fault on rotor
winding, is not possible.
Static Excitation System was developed contemporarily as an alternative to brush less
excitation system. This system makes use of generators upto 160 MVA. The system has
got an excellent transient response. But the system is not free from the power cabling,
slip rings, brush gear and moreover the equipment and thus the layout of the cubical are
not compact.
PERMANENT MAGNET GENERATOR(PMG)

This is a very small 3 phase synchronous generator , in which armature windings are
located in the stator and the rotor is provided with permanent magnet poles .Since
permanent magnet poles are provided , no field winding(or excitation) is required. With
the help of PMG, the generator can build up voltage in the absence of any DC excitation.
The 3 phase AC produced in the PMG stator is rectified and fed to the main exciter field
through an AVR.
The PMG is also a high frequency generator, generally at 150 Hz or 300Hz.

VACCUM PRESSURE IMPREGNATION

Preheating of the stator 60C, Duration : 1 Hour

Vacuum Drying at 60C, 0.2 mbar Duration: ~16-18 Hours
Entire
stator
assemblies
are
immersed
into
liquid
thermosetting epoxy resin insulation and vacuum-pressure
impregnated.
Resin Temp: 60DEG. C +/- 2DEG. C, Resin Fill ~ 20 min
Resin Level: 100 mm Above job, Settling Time ~ 10 min
Pressurization:
N2 Pressure ~ 4 bar, Raising Time ~ 80 min
Holding Time: 2 Hours.
Resin is withdrawn back
Characteristics of VPI insulation system:
1) Higher mechanical bond
2) Void free resin with high mica content ensures better heat transfer.
3) High dielectric strength, low dissipation factor, hence longer electrical life.
4) Higher thermal stability, ensures class-F under running conditions.
5) Less maintenance
6) Cost effective
7) Low inflammability, hence limited damage during abnormal operations.
8) High resistance to oil, acid, alkali and moisture.
9) Manufacturing cycle is less
10) Frame size is small, machine cheaper.
11) Elastic response to thermo-mechanical stress, machine suitable peak load
operation.
12) Tan Delta temperature tie up is small,Voltage grading at ends will be effective.
VPI SYSTEM OF INSULATION
For vacuum pressure impregnation (VPI)of cage core stators up to 120 MW capacity
which, is the largest of its kind is India. This system conforms to the latest insulation
system adopted by KWU-SIEMENS technology. The stator coils are taped the porous
resin poor mica tapes before inserting them in the slots in cage core. Subsequently, the
wound stator is subjected to a special VPI process in which first the stator is vacuum

dried and the impregnated in a resin bath under pressure of nitrogen gas. Then the stator
is cured in an oven.
The main characteristic if this system of insulation is also follows:
1. Better heat transfer resulting from resin penetration into minute air gaps in between
laminations and bar insulations.
2. Low dielectric loss resulting in increased life of the machine.
3. High resistance against the effect of moisture.
4. Reduction of time cycle of manufacture.

VACUUM PRESSURE IMPREGNATION PROCESS:

Four stages of Vacuum pressure impregnation cycle
1) vacuum drying:
temperature : 60oc +/- 3oc
pressure
: 0.2 millibar
duration
: ~ 16-18 hrs
drying check: 0.06 mbar drop in 10min
2) Imprgnation:
resin temperature
: 60oc +/- 2oc
resin filling
: ~ 20 min
resin level : ~ 100 mm above
settling time : ~ 10 min
resin (epoxy bisophenol a) & hardener ratio 1:1
3) Pressurisation:
N2 pressure : ~ 4 bar
rising
: ~ 80 min
holding time : ~ 2 hrs
capacitance measurement to ensure effective
peneteation and gelling
4) Post curing:
temperature of job : 140oc +/- 5oc
duration
: ~ 20 hrs
Advantages of VPI
Longer electrical life.
Higher thermal conductivity
Lesser thickness of insulation higher voltage stress.
Small dissipation factor tip-up (void free insulation).
Better elastic response to thermo mechanical stresses
Insensitivity to high temperature and temperature changes(suitable for gas
turbine application).

Low inflamability
Higher resistance to effect moisture
Higher chemical resistance to corrosive gases,lubeoils,acids&alkalis.
Lesser manufacturing cycle of machine.
Higher p/w ratio ,lower cost of machines.

BRUSH GEAR
In order to effectively supply excitation current to the rotor winding, the brush gears are
robustly designed with radial type brush holders. Brushes of natural graphite composition
with low co-efficient of friction and self-lubrication properties are used, which ensure
smooth and trouble free operation. The brush gear is either fixed on to the end of the
stator end covers or bearing of is mounted separately on a pedestal. Depending on the
requirements, generators are provided with on-load brush changing gears.
The advantages of this arrangement are:
* constant spring tension over the entire brush wears.
* Brush changeover without stopping the machine.
* safety of the personnel due to provision of insulated handle.

INTRODUCTION TO TESTING OFTURBOGENERATOR

Testing is an activity, which basically evaluates a component, and or a product (built up
of component assemblies) as to whether it has the technical capability that has been built
into it by way of design, materials, and technological processes employed while
manufacturing and workmanship.
As such, testing activities can broadly be classified in to a number of categories as
follows:
Type tests.

Routine tests.
Process tests.
Prototype tests.
Random sampling tests.
Endurance tests.
Research and development tests.
Environmental tests.
Investigatory & maintenance tests.
Acceptance tests.

 Commissioning & site tests.

TESTING OF TURBOGENERATOR

Measurement of dc resistance of stator and rotor winding.

Insulation resistance of stator winding.
Insulation resistance of rotor winding.
High voltage test.
Phase sequence test.
Determination of occ.
Determination of scc.
Overspeed test.
Efficiency determination by separation of losses.
Vibration measurements.
Impedance test of rotor winding.
Heat run test of rotor winding.
Heat run test in mechanical,scc and occ.
Sudden three phase short circuit test.
Advantages of testing
Provides quality assurance.
Meets the requirements of legal & contract requirements.
Reduction in rework cost.
Ensures process capability & develops checklist.
Increases confidence levels in manufacture.
Provides data for optimization of design.
Helps in building of Safety & general O&M manual.
Establishes control over raw materials.
Important points for testing
Have an approved procedure.
Tabulate test levels / stages.
Check the testing equipment before use.
Calibrate the test equipment & instruments.
Ensure interlocks of the equipment
Log the results in proper formats.
Analyse failure & submit a comprehensive report for repair / replacement.
PERFORMANCE TESTS ON TURBOGENERATOR:
With the increasing trend on standardization every country has its National Standards
covering a wide range of subjects, In India, the Indian Standards are valid and
applicable. The machines produced at Hyderabad fully conform to Indian and also
International Standards, and many machines are being exported to various countries. The
performance tests on turbo generators include the following

Measurement of Insulation resistance.

Measurement of ohmic resistance of windings in cold state.
Applied H.V. tests.
Measurement of vibrations and mechanical losses.
Measurement of no load characteristics.
Measurement of short circuit characteristics.
Determination of excitation on load and checks of voltage rise (regulation).
Measurement of leakage and potier reactances.
Measurement of losses and determination of efficiency.
Heat run tests.
Retardation test.

Testing
Routine Tests
DC cold resistance
Mech. run & vibration meas.
Meas. Shaft voltage
Meas. Of rotor Impedance
IR test of st & rt windings
HV test of st & Rt windings
Phase Sequence
Meas. Of PI of stator winding
Mechanical Balance
Over speed test (120%)
Determination of by separation of losses method
OC, SC test
Type Tests
Temperature rise test
Sudden 3 SC test
Determination of reactance & Time const.
Voltage Waveform
TEST PROCEDURE
During manufacturing of Turbo-generators the following stage tests are to be carried out
on individual components to ensure quality of the product and to reduce last minute
delay during acceptances tests. The standards for these tests will differ from plant to
plant.
Stator
Checking up of Resistance temperature detectors while core building.
Ring flux test.

 Tan delta measurement on stator winding after impregnation.

H.V. test on coils during manufacturers and assembly.
Capacitance measurement.
Rotor
H.V. test on excitation connecting leads.
H.V. & inter- turn insulation tests on field coils during the winding process.
Impedance measurement field coils.
Over-speed test

Over-speed test involves mechanical running of the rotor at the prescribed

% over-speed for the stipulated period of time. It is later subjected to a very
close mechanical inspection to investigating into the effects of over speed if
any.
The rotor is balanced to the required levels as per standards. This brings us to
measurement of characteristics and losses of the generator.
Measurement or determination of efficiency of the machine is an important step.
For determination of efficiency, losses measurement on the drive system is to be done and
derive machine losses by subtracting drive motor losses.
Determination of efficiency
Having measured the losses, the efficiency can be estimated from the formula.
Efficiency =(input losses / input = output / (Output + losses)
Tolerance on guaranteed efficiency is 0.1 (1-efficiency) when measured by summation of
losses method.
Measurement for leakage & potier reactance
Leakage reactance is measured on the stator alone when winding is completed. The
procedure involves supplying the winding from a 3-phase variable voltage source and
measuring currents voltage and power at the stator terminals. Depending on the source
capacity upto 0.25In may be passed. Potier reactance as per accepted standard practices
is taken as 0.6 to 0.65 of total leakage reactance. It can alternatively be calculated from
the zero power factor test measurements.
Sudden short circuit tests:
Sub-transient reactance, transient reactance can be determined by sudden short circuit
tests on Turbo-generator. Standards require that the turbo-generator must be capable of
withstanding a sudden short circuit at its terminals at rated voltage conditions.
The sudden short circuit switch is of a special type and its blades must close
simultaneously. Use of a high speed, multi channel recorder or electronic controller is
involved to record transient data.
Line-to-Line sustained short circuit test
The negative phase sequence reactance is can be determined from the line-to-line
sustained short circuit test.
Negative phase sequence reactance (X2) = P / 3. (Ik2)2
where P = Power measured and Ik2 is negative phase sequence current measured during
line-to-line sustained short circuit test.
Line to line and to neutral sustained short circuit test
From this test zero phase sequence reactance can be determined.
Zero phase sequence reactance (Xo) = Vo / Io.

Where Vo = Voltage from measured in open phase voltage and Io is current measured in
line to neutral during line to line sustained short circuit test.
Retardation test for determination of Moment of Inertia
The machine speed and time are noted during free coasting down of the machine.
Moment of inertia =(4 x 365000 x P x T )/ N2 Kg-m2
where: P = Power input in kW to keep machine at rated speed. N = Rated Speed in rpm.
T time in seconds from curve. (Tangent drawn at rated rpm)

TESTING OF TURBOGENERATOR
Objectives of testing
Testing is the most important process to be conducted on a machine after it is
designed. The testing of machine is necessary primarily to establish that the machine
performance complies with the customer specifications. Tests ensure that the piece of
equipment concerned is suitable for and capable for performing duty for which it is
intended.
Testing is done under condition simulating closely as possible to those, which will
apply when the set is finally installed with a view to demonstrate to purchasers
representative its satisfactory operation. Test provides the experimental data like
efficiency, losses, characteristics, temperature limits, etc. for the use of design office,
both as confirmation of design forecast and also as basic information for the
production of future designs.
Introduction
With ever increasing rating of the modern turbo generators and reliability of service
expected, testing at manufacturers works has become of paramount importance. The
machine performance is evaluated from the results of the equivalent tests.
Advantages of testing
Provides data for optimization of design
Provides quality assurance
Meets the requirement of legal and contract requirements.
Reduction in rework cost.
Ensures process capability and develops checklist.
Increases confidence levels in manufacture.
Establishes control over raw materials.
Helps in building of safety and general operation and manual.
TYPES OF TESTS
Tests on turbo generators are classified under the following headings, which is also the
order in which these are performed during the course of manufacture.
1.Tests on the materials and components during the manufacture so as to control the
quality of the materials in process also known as Process tests.
2. Performance tests on the machine to prove the performance of the generator in
accordance with the required standard.
TESTS DURING MANUFACTURE/ PROCESS TESTS:
Tests on rotor winding
Tests on stator coils.
Balancing and over speeding of rotor.
Rotor winding

The rotor coils and their insulation are subjected to a high stress when in normal
operation. Thus a thorough inspection of these is necessary before putting them in the
rotor slots as otherwise any replacement of the faulty insulation or cell would
necessitate removing the coil binding rings and the wedges, which is a cumber job. A
series of graded voltage tests are conducted on the rotor cell and coils dusting assembly
and also when finished to test its electrical strength against likely creep age to ground or
inter turn breakdown.
Tests On The Rotor Coils
1. Between turns
The rotor coils turns are made up of a number of turns which are formed in halves
and then assembled with their inter turn insulation and boned with an adhesive in the
steam heat press. Although the normal working voltage per turn is very small, a turn
to test of 240 volts is done to exercise quality control.
2.Top turn trough
The insulation the top and bottom of the rotor slot provides adequate and safe creep
age distance between copper and rotor steel, in case of slotted copper 500 volts for one
minute to test the top trough.
3. Collecting leads:
A high voltage equivalent to the shipping test plus 1500v is applied to the collector
leads when fitted in bore with studs of seals fitted but before connecting to the
windings.
Tests on stator coils
As per the standards the stator winding has to be subjected to a shipping pressure
test of (2 x line voltage +1kv). This power frequency voltage applied for one
minute.
In order that machine when found with stands this final voltage test and any faulty
coil is eliminated during various stages of coil manufacture and winding. Because
of the continued application of HV tests overstress the winding insulation, the
voltage is reduced in various stages.
Tests between parallel strips
This is a test of strip insulation provided for eddy emf, on low voltage at the order of
350V for 3 seconds is applied.
Coils in manufacturing and Winding Sections
When the coils are first tested, a voltage of 8kV in excess of shipping pressure test is
applied, and this voltage tests are repeated.
Tests on Thermocouples:
1000V Megger test is applied to the thermocouples.
Balancing and over speeding of rotors
Balancing
One of the most important preliminaries to testing is that of balancing the rotors.
Before over speeding, the rotor is dynamically balanced, in cold as well as hot
conditions. A set of run up and run down is taken sure those critical speed is well away
from the running speed.

Over Speeding
In order to check the soundness of all parts and fitting on rotor assembly, the rotor is
run at an over speed of 14% for five minutes or 30% for one minute.
PERFORMANCE TESTS/ TESTS ON COMPLETED MACHINE:
The machine is assembled and erected at the heavy rotating plant test bay for test.
Dry out insulation resistance of rotor & stator windings
Before starting with running tests, the stator windings are dried out by
circulating current in the winding from an external dc source Input of power is
so controlled as to limit the temperature of the end windings to a maximum of
800C by thermometer.
Progress of dry out is observed by one minute insulation resistance reading
with 1000v Megger. With the application of heat, the insulation resistance will
initially drop and then will rise again over a period of time and finally becomes
approximately constant temperature. Ration of ten-minute reading i.e.
polarization index, when more than 2 gives an indication of good dry out.
Insulation resistance readings of rotor winding to ground are taken.
Resistance of machine windings
Measurement of cold winding resistance, both for stator and rotor must be very
accurate
since it forms the basis of
Calculating copper under cold and hot conditions
For determining the rise in temperature of rotor winding by resistance method at the
end of temperature test.
All precautions are taken to ascertain correct temperature of the winding white
measuring cold resistance. Since the winding resistance of turbo generator is quite
low: a modified form of wheat stone bridge i.e. Kelvins double bridge does away
with the necessity of accounting for the resistance of loads. Resistance between phases
for stator and between slip rings for is recorded along with the cold winding
temperature at the time of measurement.
Phase sequence test
The phase sequence test is to check the agreement of the terminal markings that have
been specified using the Phase Sequence Indicator.
Zero excitation rated speed run
By wattmeter method when condition is steady. From the result of above test after
deducting drive motor in gear losses, friction and wind age losses of the machine
under test are computed. These losses are for rated speed. Bearing oil quantities with
inlet temperatures of oil can yield calculations for bearings loss. From a previous data
on seal face losses determined from a prototype test, the total friction loss in the
bearings and seals can be difference. Since bearing loss is computed for design office
use by the difference. Since bearing loss goes to oil, any heat carried out on the
unexcited machine will give temperature rise due to wind age.
PERFORMANCE TESTS
The performance tests on the turbo generator are classified as:
- Type tests
- Routine tests
- Heat run tests

TYPE TESTS
These are specially requested tests form the customer. They are not performed on all
machines i.e., they are specific to machine. They include
- Mechanical measurement of leakage reactance of stator winding
- Measurement of residual voltage of stator winding at rated speed
- Line to line sustain short test and determination of negative sequence
reactance [X2]
- Line-to-line and neutral sustain short circuit test and determination of
negative sequence reactance [XO]
- Retardation test for determination of GD2 Measurement of leakage
reactance of stator winding
- This test is done on the stator winding with out rotor, generally before
assembly on test bed for running test.
- Purpose
To determine total leakage reactance
To determine potier reactance
To determine armature leakage reactance
To determine leakage reactance, a search coil of adequate number of turns is
installed securely with in the stator bore with a flexible and well-insulated
copper wire. The coil span shall be of full pitch with all four sides as closely in
contact with fore as possible if one side of the coil is on the top of slot no one,
the other side of the coil shall be on the top of the slot number n.
where, n = [total no. of slots / total no. of poles] + 1
After connecting meters, variable voltage is applied to the stator windings such that
the stator current reaches to 30% of rated current or maximum capacity of thyristor set
which ever is less and meter reading are noted down.
(a) Evaluation of leakage reactance
(b) The different leakage reactances are evaluated as follows:
i) Base impedance [Xn] = En / 3In ohms
where En = rated line to line voltage
In = rated line current
ii) Total armature leakage reactance [XL] = (Z2 R2)
where Z = U/ 3I,
R = P/ 3 I2
U = voltage measured during the test
I = current measured during the test
P = power measured during the test
As the value of R i.e., stator winding resistance per phase is negligible compared
to Z, measurement of P is not required.
XL = Z = U/ 3 I ohms
% XL = 100(XL / XN)
iii) Potier reactance % XP = a ( % XL)
where a = 1 for salient pole machine and
0.63 for cylindrical pole machine
*Figure 4.1 Single line diagram of measurement of leakage reactance

Measurement of residual voltage of stator windings at rated speed

After the open circuit test, the machine is gradually de-excited and the residual
voltages of stator windings are measured at rated speed, across the three phases.
Line-to-line sustained short circuit test and determination of negative sequence
reactance
The line-to-line sustained short circuit test is carried out by short circuiting and two
line terminals of the stator winding using current transformer with the machine driven
at rated speed and excited. The following parameters are recorded at three values of
the short current limited to 30% at rated current.
- Short circuit current (IK2), through current transformer
- Voltage between the open line terminal and one of the short circuit terminals
Uk2, through potential transformer.
- Active power p.
Evaluation of negative sequence reactance (X2)
(i)
X2 = P / 3. (I K2)2 ohms
where P = power measured during the test
IK2 = line-to-line short circuit current measured during the test %X2 =
100(X2/Xn)
Line- to-line and to neutral sustained short circuit test
The line-to-line and neutral short circuit test is carried out by short-circuiting two line
terminals and shorted to the neutral using current transformer. The machine is driven
at rated speed and excited. The following values are recorded at several values of short
circuit current.
-

Neutral current (Io), through the current transformer

Voltage between the open line terminal and neutral (V 0) through potential
transformer
Evaluation of zero sequence reactance
Zero sequence reactance is calculated as follows:
XO = VO / IO ohms
where VO = line to neutral voltage
IO = line to neutral current measured during the test
% Xo = 100 (Xo / Xn)
Note: Minimum time is taken for the test because serious overhang winding heating
may result, if current is sustained for a longer time or raised to too high a value.
Redardation test for determination of GD2 (Gravitational deterioration)
The machine along with the drive system is run at rated speed and drive motor input
power is noted. Then speed is increased by 1hz corresponding rpm over the rated
speed and at the stage, the machine is tripped by opening the in-comer circuit breaker
of drive system. Time and speed are noted with an interval of 5 seconds upto 30
seconds, with an interval of 10 seconds upto 1minute and so on till the machine comes
to stand still.
Evaluation of GD2
GD2 is calculated as follows:
Time versus speed curve is plotted on a graph paper, taking X axis as time and Y-axis
as speed. A tangent is drawn at rated speed point on the curve, which meets the time
axis at point T2.T1 is the point corresponding to rated speed.
GD2 = (365000*P*T) /N2 kg-m2

Where,
P = Mechanical losses in kW
T = Time in seconds = (T2 -T1)
N = Rated rpm of the machine
2
GD of machine = GD2 measured GD2 of drive system (known)
ROUTINE TESTS
These tests are carried out on each generator to ascertain that it is electrically and
mechanically sound. These tests are carried out on different machines and are
classified as
Static tests
1. Measurement of insulation resistance of stator & rotor windings before and
after high voltage test (machine at rest).
2. High Voltage test on stator & rotor windings (machine at rest).
3. Measurement of Polarization Index of stator winding.
4. Measurement of d.c resistance of stator & rotor windings in cold condition.
5. Measurement of d.c resistance and insulation resistance of resistance
temperature detectors and thermocouples.
Running tests
1. Mechanical run and measurement of vibrations at rated speed.
2. Measurement of mechanical losses, short circuit characteristic and losses.
3. Measurement of mechanical losses, open circuit characteristic and losses.
4. Measurement of shaft voltage.
5. Checking of phase sequence.
6. Measurement of Rotor Impedance (rotor inside stator).

Static tests
Measurement of insulation resistances of stator and rotor windings before and
after high voltage test:
Equipment:
a) Megger (1000V/ 2500V)
b) Earthing rod and earthing wire/ cable.
- Insulation resistances of the stator and rotor windings are measured
separately before and after high voltage test using 2500V Megger for stator
and 1000V for rotor winding. These values are taken at 15 seconds and at 60
seconds. Absorption coefficient of insulation is found out as,
Insulation resistance at 60 seconds
Absorption coefficient = -----------------------------------------Insulation resistance at 15 seconds
- This value for H.V. test should be approximately 1.5
Minimum insulation resistance value
The minimum value of insulation resistance (Rm) at 60 seconds recommended as:
-

Rm = (KV + 1) megaohms.
Where KV is voltage in kilovolts to be applied for test.
In practice a fairly high value is obtained.
With dry winding its value will be somewhere in the vicinity of 2 or even
more. With damp winding it will decrease to somewhere near 1. Absorption

coefficient value of 1.8 and 1.7 may be satisfactory, while a value below 1.5
indicates a damp machine.
- The winding is discharged to earth after each measurement.
Measurement of polarization index of stator winding
The polarization index of stator winding, all the three phases together is measured
using 2500V Megger after high voltage test. The insulation resistances are noted at
1minute and at 10 minutes from starting of measurement.
The polarization index is evaluated as follows:
Insulation resistance value at 10 minutes
Polarization Index (P.I) = ------------------------------------------------Insulation resistance value at 1 minute
The minimum allowable PI value is 2.0.
High voltage test on stator and rotor windings
Equipment:
1. 50 Hz A.C. High Voltage transformers and its induction regulator / input
autotransformer.
2. Potential transformer (35 or 100kV / 100V)
3. Voltmeter.
4. Binding wire.
5. Earthing rod and earthing wire / cable.
When H.V. test is done on one-phase winding, all other phase windings, rotor
winding, instrumentation cables and stator body are earthed.
The high voltage is applied to winding by increasing gradually to required value and
maintained for one minute and reduced gradually to minimum. The transformer is
switched off and winding is discharged to earth by shorting the terminal to earth using
earthing rod connected to earthed wire/ cable. The test is conducted on all the phases
and rotor winding separately.
High voltage test levels:
Stator winding: (2Ut + 1) kV = 23 kV for 11 kV machine.
Rotor winding: (10 Ue) volts.
(with minimum of 1500 V and maximum of 3500V).
where, Ut = Rated voltage of the machine (kv).
Ue = Excitation voltage.
Stator winding
Testing of stator winding involves the testing of connecting rings after the assembly
and stator bars during assembly.
Up = (2 Un + 1)
Where, Up is the final test voltage after the test run and Un is the rated voltage of
the generator.
- The connecting rings are tested for 1.2 UP for 1 minute. If there is sparking
due to less distance between the live joints, the same can be done with 1.1
UP. If the connecting rings are assembled after laying bars, they are tested
along with the bars.

The high potential is given to copper and the core is earthed. The output
voltage of the high voltage tester is continuously increased to test the voltage
level, held for 1 minute and subsequently decreased to initial level.
After the bottom bars are laid they are tested for 1 minute with 1.1 U P.
Individual strips are of each bar are tested with 220V ac for any possible
inter half shorts and inter bundle shorts.
After the top bars are laid, High voltage testing is carried out with 1.1 U P for
1 minute and they are tested for inter half and inter bundle shorts. Inter half
shorts test with 220V ac is carried out after connecting the top and bottom
bars without the connecting rings.
High voltage testing of the individual phases with 1.05 U P is carried out for 1
minute after the completion of the winding . When one phase is under test
the other phases are earthed.
Resistances of individual phases are measured .
During high voltage testing all the instrumentation cables assembled in the
machine are to be earthed.
Insulation resistance of each phase is to be measured after each high voltage
test.
Whenever bunch brazing is employed for connecting top and bottom layers,
only inter half shorts test is to be carried out.

Rotor winding
The rotor winding must be tested at various stages of its manufacture and assembly.
- The output of the high voltage test equipment is connected to the output lead
or to the winding as the case may be and shaft is earthed. The voltage is
continuously increased to test voltage level, maintained for 1 minute and
subsequently decreased to initial value.
- To test for inter turn shorts the required voltage is applied across the total
winding of both the poles and voltage across the winding corresponding to
each pole is measured and recorded.
- The final test voltage UP is ten times the rated voltage subjected to a
maximum of 3.5 kV and manimum of 1.5 kV.
- Before assembly of rotor bars HV test is carried with U P + 2000V for one
minute. Then both the poles against earth are tested with UP + 1500 V for one
minute.
- After the assembly of the rotor bars HV test is carried with U P + 1500 V for
one minute initially pole against pole and then against earth.
- After the assembly of two coils HV test is carried with U P + 1500 V for one
minute initially pole against pole and then against pole and then against
earth.
- Before the wedging is complete, winding against shaft is tested with
UP+900V for one minute. After wedging the complete winding against shaft
is tested with UP+800V for one minute.
- After pressing and curing the insulation under the retaining ring, high voltage
testing of the winding against shaft is carried out with UP + 600V for 1
minute. Then d.c winding resistance is measured.

After mounting the retaining ring high voltage testing of the winding against
the shaft with UP+400V is carried out for one minute.
- After over speeding and balancing at standstill HV testing of the winding
against the shaft with UP+200V ac is carried out for one minute.
- HV testing of the winding is carried out at 3000 rpm with 500V ac for one
minute. Then the winding is tested against the shaft with UP for one minute.
- The insulation resistance value of the winding is measured after each high
voltage.
* Figure no: 4.3 Single Line Diagram of H.V Testing of Stator Winding
Measurement of D.C resistance of Stator and Rotor windings in cold
condition
Equipment
Digital micro ohmmeter and its measuring leads.
a) Thermometer (Hg in glass)
D.C resistances of stator and rotor windings are measured separately using
digital micro ohmmeter. The instrument terminals are connected to the machine
terminals and proper range in meter is selected. The stabilized reading is
recorded.
Ambient temperature from Hg in glass thermometer is recorded. The stator
resistance temperature detectors values are noted and average value of stator
winding temperature is evaluated.
1.4.1. Evaluation of resistance at 20OC:
- Evaluation of resistances at 20OC (R20) is done by using formula:
- R20 = {Rt (235+20)} / (235 + T) milli ohms
- Where, R20 = Resistance at 20OC in milli ohms
- T= The average temperature of the stator winding in degrees centigrade.
Rt = Measured resistance of the winding in milli ohms
- Variation in maximum and minimum values of d.c resistance of 3 phases of
stator windings up to 5% is acceptable.
Measurement of D.C resistances and insulation resistances of Resistance
temperature detectors
The d.c resistances and insulation resistances of resistance temperature detectors
are measured using multimeter and megger respectively and recorded.
Measurement of Capacitance and Tan of stator winding
a) The capacitance measurement of stator winding is done using schering bridge and
standard capacitor. For a 3 phase synchronous machine, the windings are symmetrical
and the value of capacitance is arrived by measuring in arrangements I & II.
Arrangement I:
H.V. application to one of the phases and remaining phases are connected to body of
stator. This gives the value of Cg+2 C m, where Cg is capacitance of winding with
respect to ground and Cm is with respect to other winding (mutual
capacitance).
Arrangement II:
H.V. application to all the phases. This gives the value of 3Cg..
b) Equipment:

a)
b)
c)
d)
e)
f)
g)

50 Hz A.C. high voltage transformer (T90, 0 - 35kV)

Standard capacitor (100 / 1000 pF).
Schering bridge
Isolation shunt box
Connecting H.T. cables.
Earth wire with earthing rod.
Voltmeter.
h)Megger (1000V).
i)Null Indicator (galvanometer).
j) 1- phase supply source for null indicator.
c) Test preparation:
i)
The stator body is isolated from ground by placing insulation
packing between the body and the base.
ii)
Connections to the Schering Bridge, standard capacitor, Null
indicator and transformer are done as per figure 4.4 for the
selected arrangement.
iii)
Measurements are taken at voltages 0.2Un to 1.0Un in steps of
0.2Un.
iv)
The H.V. supply is switched on and raised to the required value.
The bridge is balanced with the proper selection of variable
resistances (R3+S) & the capacitance C4 and readings are
recorded. After all measurements, voltage is reduced to zero,
supply is switched off and windings are discharged to earth.
e) Formula used:
i) Capacitance:
Cn x R4 x (R3+100)
Cx = -------------------------F.
N x (R3+S)
ii) Percentage of tan
% tan = ( x R4 x C4 x 10-4 ) x 100
where, C4 & Cn are in F.
R3, R4, N & S are in .
*Figure 4.4 Single line diagram of Schering bridge for measurement of
capacitance and tan
RUNNING TESTS
These tests are run after assembly of machine on test bed.
Equipment:
a. D.C motor drive system.
b. Bearing lubrication system.
c. Cooling water system.
d. Current transformers 2 nos.
e. Potential transformers 2 nos.
f. D.C current shunts 2 nos.
g. AC/DC Power analyzer.
h. Phase sequence indicator.
i. Multimeter for continuity checks.

j. Vibration monitor.
k. Resistance temperature detectors monitor.
l. 50 Hz A.C High voltage test equipment.
m. Meggers.
n. Micro ohmmeter.
o. Connecting leads/copper strips and earthing cables rods etc.
Mechanical run and measurement of vibrations at rated speed
The turbo-generator under test is assembled separately without coolers and enclosures
(if any), on a test foundation frame using its own bearings and coupled to a calibrated
d.c drive motor with gearbox of suitable capacity (1900kW/ 1300kW/ 750kW). The
brushless Exciter and Permanent magnet generator are mounted on the overhang of
the generator rotor. Testing of turbo-generator, brushless exciter and permanent
magnet generator are done separately. The power to the drive motor and the field of
the generator are drawn independently from the thyristor converters suited in electrical
machine controlled rooms and controlled from test gallery independently.
Before running the machine ensure
Lubricating Oil is flowing through bearings and the gear box.
- All the instruments are working
- Roll the machine and check all the parameters. Slowly raise the speed to onesixth rated speed. Observe slow roll vibrations, temperature and oil flows.
Raise the speed to one-third rpm slowly and record the vibrations,
temperature and oil flows.
- The vibrations are measured at rated speed on both the bearing housings
(pedestals) in horizontal, vertical and axial directions with the help of
vibration meters, which are internally connected to the monitor and the
vibrations, are noted in the form of graphs.
- The temperature of stator is monitored by monitoring resistance temperature
detectors embedded in core, tooth and winding. Now raise the speed to two
third the rpm by observing all the parameters, critical speed and record them.
The machine is rolled and run at rated speed after ensuring the bearing oil
and left at rated for stabilization of bearing temperatures.
Measurement of mechanical losses, short circuit characteristic and losses
- The machine is prepared for short circuit characteristic using current
transformers and shorting links as shown in figure 4.5
- The machine is run at rated speed and drive motor input voltage and current
are noted and m/c is excited gradually in steps, at 20%, 40%, 60%, 80%,
90% and 100% In
(In = Rated current of machine).
At each step the following parameters are noted:
1) Stator current (Ia & Ib)
2) Rotor current (If) corresponding to stator current.
3) Drive motor voltage (Vd) and current (Id) corresponding to stator current.
4) Resistance temperature detectors readings at rated stator current (100% In).
5) Bearing vibrations at rated stator current (100% In).

The excitation is reduced and cut off. The speed is reduced and the machine is
cooled at lower speed. The temperatures are checked from machine resistance
temperature detectors readings. The machine is stopped when it is sufficiently
cooled down. (The stator winding temperatures to be less than 60OC).
From the above data, the characteristic curves are plotted as follows:
a) % In versus If.
b) % In versus machine looses in kW.
*Figure 4.5 Single line diagram for short circuit characteristics
Measurement of mechanical losses, open circuit characteristic and losses
The machine is prepared for open circuit as shown in the figure 4.6.
- The machine is run at rated speed and drive motor input voltage and current
are noted and m/c is excited gradually in steps, at 20%, 40%, 60%, 80%,
100% and 120% En (En = rated voltage of machine).
At each step the following parameters are noted:
1) Stator voltages (Vab,Vbc,Vca)
2) Rotor current (If) corresponding to stator voltage.
3) Drive motor voltage (Vd) and current (Id) corresponding to stator voltage.
4) Resistance temperature detectors readings at rated stator voltage (100% En).
5) Bearing vibrations at rated stator voltage (100% En).
The excitation is reduced and cut off. The speed is reduced and the machine is
cooled at lower speed. The temperatures are checked from machine resistance
temperature detectors. The machine is stopped when it is sufficiently cooled
down. (The stator winding temperatures to be less than 60OC).
From the above data, the characteristic curves are plotted as follows:
c) %En versus If.
d) % En versus machine looses in kW.
* Figure 4.6 Single line diagram for open circuit characteristics
Measurement of shaft voltage
Phase voltage of generator is measured using multimeter or a high input impedance
a.c voltmeter across the two ends of the rotor when machine is in open circuit test
condition at 100%En.
Checking of phase sequence
Phase sequence of generator is checked using a phase sequence indicator across
potential transformer output terminals when machine is in open circuit condition at
100%En.
Measurement of rotor impedance (Rotor inside stator)
Equipment:
a) 50Hz (Power frequency) A.C source.
b) AC/DC Power analyzer.
c) Current transformer (50A/5A or 100A/5A)
d) Connecting leads.
Connections are made as per the figure 4.7
A variable 50 Hz A.C. voltage of single phase is applied across the slip rings
/input leads and readings of voltage and current are noted down from 50V to
200V in steps of 50V. This test is done at 1/3, 2/3 and at rated speed.

Evaluation of impedance
Using formula does evaluation of impedance:
Z = V /I ohms
where Z = impedance in ohms
V = voltage in volts
I = current in amperes
Impedance measurement:
- At rated rpm (Rotor inside stator).
- At standstill (Rotor inside stator).
- At standstill (Rotor outside stator).
*Figure 4.7 Single line diagram for measurement of Rotor impedance
EVALUATION OF EFFICIENCY
Efficiency of Turbogenerator
Introduction
Among some of the parameters, which decide the quality of the machine, like Short
circuit ratio (S.C.R.), reactance & time constants, moment Of inertia, efficiency,
Efficiency of a machine is put under guarantee clause by most of the customers. An
efficient machine adds in economy in performance and brings exclusive respect to the
manufacturer. Most of the manufacturers brand their product on efficiency. The
demand is more inclined towards efficiency. Product efficient machine or loose the
market has become todays endeavor.
Efficiency is defined as The ratio of output to input expressed in the same units,
generally it is expressed as a percentage.
The output of the machine always losses of the machine subtracted from the input.
Thus %Efficiency = 100{(output) / (output + losses)}
The Total loss consists of the following component losses
Excitation Circuit Losses:
a. Field I2R loss: The I2R loss in the field winding.
b. Main rheostat loss: The loss in the rheostat in the main exciting winding.
c. Electrical loss in the brushes: The summation of I2R losses in the brushes and
the connectors and brush contact loss.
d. Exciter loss: All the losses of exciter mechanically driven from the main
shaft which forms part of the complete unit and is used solely for exciting the
machine, together with the losses in the rheostat in the field circuit of such an
exciter.
Losses independent of Current
a. Core loss: Core loss at no load, rated speed and rated terminal voltage.
b. Bearing friction loss: only losses in the bearing supplied with the equipment
will be included.
c. Total windage loss: The total windage loss in the machine and exciter, if any,
including the power absorbed in the fans forming an integral form of the
machine.
d. Brush friction loss: The brush friction including that of the exciter if
mechanically driven.
Direct load loss: The I2R loss in primary windings determined from the current and
the resistance of the winding.
Stray load loss:

a) Stray load loss determined from the primary windings determined

from the current in the conductors.
b) Stray load loss in the conductors.
EVALUATION OF EFFICIENCY
After completion of routine tests, efficiency of the machine evaluated.
The following sequence of calculation is followed.
1.Open circuit characteristics is plotted on a graph paper from open circuit
characteristics results by selecting X axis as field current and Y- axis % of rated
voltage. Values of field current at 80%,100&,115%,130%En are taken from the curve.
2.Short circuit characteristic is plotted from S.C.C results by selecting X axis as
field current and Y axis as % of rated current. Values of field at 100% In are taken
from the curve.
Turbo generator looses: ref. Fig. 4.8.
Air gap line for open circuit characteristics is drawn and field current for air gap line
at 100%En is obtained.
Copper loss characteristic is plotted from S.C.C results by selecting X axis, as %of
rated current and Y axis as losses in kW. The value of copper loss (kW cu1) at
100%In is taken from the curve.
Iron loss characteristic is plotted from O.C.C results by selecting X axis, as %of
rated current and Y axis as losses in kW. The value of iron loss (kW fe) at 100%En
is taken from the curve.
Drive motor with gearbox losses:
From calibration curves of drive motor used testing following data is taken:
Drive motor iron losses at voltage Vd
= kw1
Drive motor copper losses at current Id = kw2
Drive motor loss
(kw3)
= kw1+Kw2
Drive motor iron losses at 100% In
= kw4
Drive motor copper losses at 100% In
= kw5
Drive motor loss at 100% In
(kw6)
= kw4+k5
Drive motor iron losses at 100 En
= kw7
Drive motor copper losses at 100% En = kw8
Drive motor loss at 100% En (kW9)
= kw7+kw8
3. Mechanical losses of the Turbo generator + Drive unit:
i). Average mechanical losses (kW mechanical.) = Average of mechanical losses
before Short circuit characteristics and open circuit characteristics (kw average
mechanical)
ii) Losses at 100% In i.e. 100%In mech. = kW average mech. + (kW6 kW3)
iii) Losses at 100% En i.e. 100%En mech. = kW average mech. + (kW9 kW3)
Machine losses:
a. Mechanical losses (Pmech) = kW avg mech. kW3
b. Stator copper losses at 100% In (Pcu1) = kWcul kW 100%In mech.
c. Stator iron losses at 100% En (Pfe) = kWfe kW 100%En mech.
d. Excitation losses: This shall be taken as 5% of rotor copper losses.
e. Brush drop losses: In case of machine with conventional excitation system
with slip rings on rotor, the brush drop losses are calculated taking voltage

drop of 1.0 volt each polarity multiplied by the rated excitation current. For
brushless excitation system, this loss is non-existent.
To obtain field currents of the turbo generator at 25%, 50%, 75% & 100% loads
all the data required from the test results are fed to the computer program. The
output gives field currents, rotor copper losses and excitation losses. After
obtaining the machine losses including exciter mechanical losses (if any), stator
copper losses, stator iron losses, rotor copper losses, excitation losses, brush
drop losses (if any); all the losses are added to get total loss.
Percentage efficiency (%) is evaluated as follows:
Output
%Efficiency = 10 0 X
-----------------------Output + total losses
Evaluation of short circuit ratio (S.C.R):
From the test data S.C.R is calculated using formula:
Field current at 100% En from open circuit test
Short circuit ratio = ---------------------------------------------------------Field current at 100% In from Short circuit test
Evaluation of % inherent regulation:
From the test data % inherent regulation is calculated using formula:
Eo - En
% Inherent regulation = ----------- X 100
En
where, Eo = Open circuit voltage at full load estimated field current
En = Rated voltage
TESTING OF BRUSHLESS EXCITER
This test procedure covers the procedure for routine tests on brushless exciter and
permanent magnet generator.
Tests conducted on brushless exciter
Open circuit characteristic.
Measurement of D.C. resistance of armature windings and main pole winding.
Tests conducted on Permanent Magnet Generator
- Measurement of output voltage at rated speed.
- Checking of phase sequence and measurement of frequency.
- Measurement of load characteristic.
- Measurement of insulation resistance value before high voltage tests.
- Measurement of D.C. resistance of stator winding.
SETUP
The brushless exciter mounted on the overhang of the generator rotor shaft but
electrically not connected to the generator rotor. The rotor shaft is mechanically
coupled to a calibrated D.C drive motor with its gearbox and is run at rated speed. The
exciter is excited from a separate DC source and output will be taken through the slip
rings to a water load resistance. The source of electrical power is derived from the
thyristor converters located in an independent machine room and the operation is
controlled from the test gallery.

Output terminals of the machine under test are connected to the outlet boxes of the test
pit, which in turn connects to the terminals in the control gallery where the
measurement is done.
Equipment
- D.C. motor drive system
- Bearing lubrication system
- D.C. voltmeters
- D.C. current shunts
- Phase sequence meter
- Water load resistance bank
- Current Transformers
- A.C Ammeters
- A.C. voltmeters
- Frequency meter
- Vibration probes and Vibration monitor
- Megger
- 50Hz A.C High voltage test kit
- Micro ohmmeter
Test Procedures Of Brush less Exciter
Open Circuit Characteristics
The machine is prepared for open for open circuit characteristic and resistance (
=500ohms) is connected across the slip rings. This is to allow a minimum current to
pass through the diodes for voltage measurement. The machine is run at rated speed
and the field winding is excited gradually in steps up to rated output voltage.
At each step, following parameters are noted:
Va = Output voltage of the exciter
Ia = Load current of the exciter
From the above data characteristic curve is plotted as Va versus If.
Load Magnetization curve
- The machine is prepared for the load magnetization characteristic. A variable
water load resistance is connected across the slip rings.
- The machine is run at rated speed, load breaker is closed and the machine is
excited gradually in steps. The load resistance is maintained at R40 (R40:
Turbo generator rotor resistance at calculated for 400C) by adjusting the
water load resistance.
- At each step, following parameters are noted:
- Va : Output voltage of the exciter
- Ia: Load current of the exciter
- If: Field current of the exciter
- And bearing vibrations at rated load.
- Test is repeated for load resistances R70 and R100.
- From the above data curves (Ia versus If) are plotted at each load.
Measurement of insulation resistance and HV tests
- Before performing these tests, all the diodes are shorted by the copper wire.
This is to protect the diodes during meggering and HV tests on armature
windings. Rotor and stator bodies are properly earthed. IR values of the

windings are measured with 500V or 1KV megger and values at 15 and 60
are noted before and after high voltage tests.
- Minimum insulation resistance value:
- The minimum value of insulation resistance (Rm) at 60 seconds is
recommended as:
Rm = (kV+1) mega ohms
- where kV = Voltage in kilo volts to be applied for H.V. test.
High voltage test is done on individual windings using high voltage test kit by
regulating primary voltage to the transformer. Slowly HV is reached and maintained
for 1 minute and is reduced to zero. The earth rod then discharges the object and the
IR values are taken. When this test is done on one winding, the other windings are
earthed.
Measurement of DC resistances of Armature windings and main pole winding
After dynamic tests the machine is allowed for cooling and when it is sufficiently
cooled, the DC resistances of all the three armature windings and main pole windings
are measured separately by the micro-ohmmeter. The ambient temperature is also
recorded and the evaluation of resistances at 20OC is done by using the formula:
R20 = Rt (235+20)/(235+T)
R20 = DC resistance at 20deg
Rt = DC resistance of the winding at t deg
T = Temperature of the winding in deg
Test Procedure of the permanent magnet generator (PMG)
The permanent magnet generator is assembled along with the brushless exciter on the
generator rotor shaft. The output is connected to a three-phase resistance load
(variable in steps). As permanent magnet generator has got permanently magnetized
field poles, it starts generating voltage right from the start of mechanical run.
Measurement Of Output Voltage At Rated Speed
The machine is run up to rated speed and the output voltages Vuv, Vvw, Vwu are
measured. To counter check, voltage is also measured at speeds of 1/3, 2/3, and
rated speeds.
Checking Of Phase Sequence and Measurement of Frequency
When the machine is at 1000rpm of the rated speed, the three phases input terminals
of the phase sequence meter are simultaneously touched with the output terminals if
permanent magnet generator. The sequence indicated by the meter is recorded.
At rated speed, a frequency meter is connected across any two phases of the
permanent magnet generator PMG output terminals and frequency is measured.
Measurement Of The Load Characteristic
- Machine is run at rated speed and loaded using three-phase resistance bank
in steps up to rated load current.
- At each step, load currents and output voltages are noted.
- Load magnetization curve is drawn as phase-to-phase voltage versus load
current.
Measurement Of insulation resistance value and HV tests
- Insulation resistance value of the stator winding is measured by 500V or
1KV hand operated/ motorized megger before and after HV test.
- High voltage test is done on the stator winding using H.V test kit by
regulating primary voltage to the transformer. Slowly high voltage is raised
where,

and maintained for one minute and then reduced to zero. Winding is
discharged and insulation resistance values are taken.
Measurement Of DC resistance Of Stator Winding
After dynamic tests, the machine is allowed for cooling and when it is sufficiently
cooled, digital micro-ohmmeter measures the d.c resistances of all the three phase
windings separately. The ambient temperature is also recorded and the evaluation of
resistances at 20deg is done as shown in the figure.

NEEDED NOTES
Synchronous Speed
Ns =120 f/P
STATOR
Split casing of stator frame(VPI generators)
Core built with low loss cold rolled non-grain oriented sheet steel (CRNGO) with
low hysteresis & eddy current loss.
.Stator packets separated by radial ducts

Clamping of core by core tension bolts to eliminate core bulging

Core consolidation under heat & pressure

Gluing of end packets to reduce end core vibration and loosening of ventilation
pieces

Stator insulation with resin poor micalastic system

Assembly of RTDs & Fire Detectors

In stator winding, between bottom bar and top bar
In stator core
In hot and cold air chambers
In bearing shell
Fire detectors mounted on both sides of the stator core to detect fire inside the
generator.
SALIENT FEATURES OF DESIGNS OF BARS
Roebel bars with 3600 transposition to reduce eddy current losses high
capacity.
Double glass covered copper conductors.
Multi turn design for low capacity high voltage machines
Resin rich mica / resin poor VPI insulation.
Corona protection of straight part insulation.
Vacuum Pressure Impregnation
Preheating of the stator 60C, Duration : 1 Hour
Vacuum Drying at 60C, 0.2 mbar Duration: ~16-18 Hours
Entire stator assemblies are immersed into liquid
thermosetting epoxy resin insulation and vacuum-pressure impregnated.
Resin Temp: 60DEG. C +/- 2DEG. C, Resin Fill ~ 20 min
Resin Level: 100 mm Above job, Settling Time ~ 10 min

Pressurization
N2 Pressure ~ 4 bar, Raising Time ~ 80 min
Holding Time: 2 Hours.
Resin is withdrawn back
Advantages of VPI
* LONGER ELECTRICAL LIFE
* HIGHER THERMAL CONDUCTIVITY
* LESSER THICKNESS OF INSULATION HIGHER VOLTAGE STRESS.
*SMALL DISSIPATION FACTOR TIP-UP (VOID FREE INSULATION )
* BETTER ELASTIC RESPONSE TO THERMOMECHANICAL
STRESSES
* INSENSITIVITY TO HIGH TEMPERTURE AND TEMP. CHANGES
(SUITABLE FOR GT APPLICATION)
* LOW INFLAMABILITY
* HIGHER RESISTANCE TO EFFECT MOISTURE
* HIGHER CHEMICAL RESISTANCE TO CORROSIVE GASES, LUBE
OILS, ACIDS & ALKALIS
* LESSER MANUFACTURING CYCLE OF M/C.
* HIGHER P/W RATIO. LOWER COST OF M/C.
Rotor Design
Solid rotor forging of Cr Ni Mo V alloy steel

Silver bearing semi hard electrolytic copper conductor for rotor winding

Half coil technology for rotor winding to achieve better forming and
consolidation of end winding

Slot wedges of good electrical conductivity shorted at the end by retaining

rings
18 Mn 18 Cr retaining rings of forged non-magnetic steel shrunk fitted on the
rotor barrel

2 Nos. of axial fans mounted on each side of rotor for ventilation of

Generator with screwing type individual fan blades

2 nos. of journal bearings with insulation to eliminate bearing currents

 Vibration pickups for vibration monitoring

Testing
Routine Tests
DC cold resistance
Mech. run & vibration meas.
Meas. Shaft voltage
Meas. Of rotor Impedance
IR test of st & rt windings
HV test of st & Rt windings
Phase Sequence
Meas. Of PI of stator winding
Mechanical Balance
. Over speed test (120%)
Determination of by separation of losses method
OC, SC test
Type Tests
Temperature rise test
Sudden 3 SC test
Determination of reactance & Time const.
Voltage Waveform
BL Exciter Design
B.L. EXCITERS
NO BRUSHES
A RECTIFIER WHEEL CONVERTS THE AC OUTPUT OFTHE BLE
ARMATURE TO DC.
THEY ARE EITHER COUPLED OR OVERHANG MOUNTED
CONSTRUCTIONAL FEATURES
IT IS ALSO ANOTHER GENERATOR
THE FIELD IS ON THE STATOR UNLIKE THE TG.
THE ARMATURE IS ON THE ROTOR.
ALL THE BRUSHLESS EXCITERS HAVE INBUILT/ SEPARATELY
MOUNTED PMGS
TESTING OF GENERATOR

MEASUREMENT OF DC RESICSTANCE OF STATOR AND ROTOR

WINDING
INSULATION RESISTANCE OF STATOR WINDING
INSULATION RESISTANCE OF ROTOR WINDING
HIGH VOLTAGE TEST
PHASE SEQUENCE TEST
DETERMINATION OF OCC
DETERMINATION OF SCC
OVERSPEED TEST
EFFICIENCY DETERMINATION BY SEPARATION OF LOSSES.
VIBRATION MEASUREMENTS
IMPEDANCE TEST OF ROTOR WINDING
HEAT RUN TEST OF ROTOR WINDING

HEAT RUN TEST IN MECHANICAL, SCC AND OCC

SUDDEN THREE PHASE SHORT CIRCUIT TEST

1.0 Main Features :

An excitation system with rotating rectifiers consists of an auxiliary exciter with rotating
permanent poles and a main A.C.exciter with a stationary magnet system and a rotating 3
phase A.C. winding to which silicon rectifiers are connected.
The rotors of these two machines are coupled direct to the shaft of the main generator. As
in the case of direct coupled D.C.exciters, this makes the excitation circuit independent
of any external auxiliary system.
The main advantages of this excitation arrangement are :
No commutators
No slip-rings
No carbon brushes
No pollution by carbon dust
Minimum maintenance
High reliability.
STATOR CORE

CARRIES THE DEAD AND DYNAMIC LOAD OF STATOR WINDING

CARRIES THE MAGNETIC FLUX.

CORE BUILT WITH SILICON ALLOYED NON-GRAIN ORIENTED

STEELSHEETS (CRNGO) :LOW HYSTERESIS AND EDDY CURRENT
LOSS.

STATOR PACKETS SEPATRATED BY RADIAL DUCTS

CLAMPING OF CORE BY CORE TENSION BOLTS
CORE CONSOLIDATION UNDER PRESSURE
GLUEING OF END PACKETS TO REDUCE VIBRATION
RING FLUX TEST TO ENSURE CORE HEALTHINESS
STATOR WINDING
THREE PHASE ,STAR CONNECTED, SHORT PITCHED, DISTRIBUTED
DLL WINDING.
MULTITURN WINDING FOR LOW CAPACITY HIGH VOLTAGE M/C
ROEBEL BARS FORSTATOR WINDING
HIGH CAPACITY M/C with 3600 TRANSPOSITION TO REDUCE EDDY
CURRENT LOSSES
DGC COPPER BUNDLED TO REDUCE SKIN EFFECT
RESIN RICH MICA/RESIN POOR VPI INSULATION .
CORONA PROTECTION/STRESS GRADING .