AC Generator Construction - The Alternator Stator

Introduction
Alternating current generators or alternators as they are more popularly known are work on the principle of electromagnetic
induction and consist of a stationery armature and a rotating field rotor. In the next couple of articles we will take a brief look at
alternator construction studying its different parts one by one and learning about their construction starting with alternator stators
First of all let us start by learning what are the advantages of a stationary armature system, rather than the other way round (as
is normally the case in DC generators where armature rotates)

Since the output current of the generator is generated in the armature, it is much easier to extract this current for
external use from the stationary armature rather than from a rotating armature wherein the brushes come into the picture
and the associated challenges of using brush contacts for transferring current.
Secondly it is much easier to insulate the stationary armature winding for high voltages which are normally in the region
of over 30 KV.
Thirdly apart from insulation it is also easier to brace these windings to prevent any deformation.

The figures below show images related to stator assembly and the arrangement of coils etc

Stator Construction

Stator Frame and Rotor Construction

The stator frame is used to hold the armature windings in alternators, and in case of larger
diameter alternators (which are slow speed) the stator frame is cast out of sections and there are
holes for ventilation in the casting itself. The recent trends towards such stator construction are
more in favor of using mild steel plates which are welded together rather than using castings.

Another integral part of the stator is the stator core which is supposed by the stator frame. Actually you can see the combined
diagram of both the stator core as well as the stator frame (first of the three diagrams above). The core is constructed in the form
of laminations and the material used for the same is either magnetic iron or steel alloy. The main purpose of lamination is to
prevent loss of energy in the form of eddy currents. There are different types of armature slots provided in the core to insert the
conductors and the three various types are as follows

Wide open type slots

Semi closed type slots
Close type slots

Whereas the wide open slots are easier from the winding and repair perspective, they are also having a disadvantage that
improper distribution of air gap flux.
The fully closed one on the other hand are good from this air gap flux perspective but obviously the initial construction and labor
involved in such winding is substantially more in this case.
The semi closed presents an optimum mix of both these but then the actual design used is decided by the design specialist
based on combined effect of all factors involved.

PARALLEL OPERATION OF ALTERNATORS

Alternators are connected in parallel to (1) increase the output capacity of a system beyond that of a single unit, (2) serve as
additional reserve power for expected demands, or (3) permit shutting down one machine and cutting in a standby machine
without interrupting power distribution. When alternators are of sufficient size, and are operating at different frequencies and
terminal voltages, severe damage may result if they are suddenly connected to each other through a common bus. To avoid this,
the machines must be synchronized as closely as possible before connecting them together. This may be accomplished by
connecting one generator to the bus (referred to as bus generator), and then synchronizing the other(incoming generator) to it
before closing the incoming generators main power contactor. The generators are synchronized when the following conditions
are set:

1.

Equal terminal voltages. This is obtained by adjustment of the incoming generators field strength.

2.

Equal frequency. This is obtained by adjustment of the incoming generators prime-mover speed.

3.

Phase voltages in proper phase relation. The procedure for synchronizing generators is not discussed in this chapter. At
this point, it is enough for you to know that the above must be accomplished to prevent damage to the machines.

Sources:
http://www.brighthubengineering.com/commercial-electrical-applications/67627-ac -generatorconstruction-the-alternator-stator/#imgn_0
http://electriciantraining.tpub.com/14177/css/14177_78.htm

Synchronization of alternator means connecting an alternator into grid in parallel with many other alternators, that
is in a live system of constant voltage and constant frequency. Many alternators and loads are connected into a grid, and all the
alternators in grid are having same output voltage and frequency (whatever may be the power). It is also said that
the alternator is connected to infinite bus-bar.
A stationary alternator is never connected to live bus-bars, because it will result in short circuit in the stator winding (since there
is no generated emf yet). Before connecting an alternator into grid, following conditions must be satisfied:

1.

Equal voltage: The terminal voltage of incoming alternator must be equal to the bus-bar voltage.

2.

Similar frequency: The frequency of generated voltage must be equal to the frequency of the bus-bar voltage.

3.

Phase sequence: The phase sequence of the three phases of alternator must be similar to that of the grid or bus-bars.

4.

Phase angle: The phase angle between the generated voltage and the voltage of grid must be zero.

The first condition of voltage equality can be satisfied by a voltmeter. To satisfy the conditions of
equal frequency and identical phases, one of the following two methods can be used:
(i) Synchronization using incandescent lamp
(ii) Synchronization using synchroscope.

Synchronization of Alternator Using Incandescent Lamp

Let, alternator 2 is to be synchronized in a grid and the alternator 1 is already
in the grid as shown in above figure. The alternator 2 is connected to grid
through three synchronizing lamps (L1, L2 and L3) as shown in above figure.
If the speed of the alternator 2 is not such that the frequency of output voltage
is equal to the frequency of the grid, there will also be a phase difference in the
voltages, and in this case the lamps will flicker. Three lamps are connected
asymmetrically, because if they were connected symmetrically, they would
glow or dark out simultaneously (if the phase rotation is same as that of busbars). Asymmetrically connected lamps indicate whether the incoming
machine is running slower or faster. If the alternator 2 is running slower, the
phase rotation of alternator 2 will appear to be clockwise relative to the phase
rotation of the grid and the lamps will light up in the order 3, 2, 1; 3, 2, 1.... If
the alternator 2 is running faster, the phase rotation of alternator 2 will appear
to be anticlockwise relative to the phase rotation of the grid and the lamps will
light up in the order 1, 2, 3; 1, 2, 3....
When the speed of the alternator 2 reaches so that, the frequency and phase rotation of output voltage is similar to that of the
grid voltage, lamp L1 will go dark and lamps L2 and L3 will dimly but equally glow (as they are connected between different
phases and due to this there will be phase difference of 120 degree). The synchronization is done at this very moment. This
method of synchronization is sometimes also known as 'two bright and one dark method'.
Drawbacks of 'synchronization using incandescent lamps' method are:

Synchronization by using incandescent lamps depends on the correct judgment of the operator.

This method does not tell how slow or fast the machine is.

To use this method for high voltage alternators, extra step down transformers need to be added as ratings of lamps are
normally low.

Synchronization of Alternator Using Synchroscope

A synchroscope is a device which shows the correct

instant of closing the synchronizing
switch.Synchroscope has a pointer which rotates on
the dial. The pointer rotates anticlockwise if
the machine is running slower or it rotates clockwise if
the machine is running fast. The correct instant of
closing synchronizing switch is when the pointer is
straight upwards.

Advantages of Parallel Operation of Alternator or Generators

When a large number of alternators or synchronous generators are connected in parallel to an infinite bus bar system having a
constant terminal voltage, constant bus bar frequency and very small synchronous impedance, then this kind of connection is
known as parallel operation of alternators.
Parallel operation of alternators is often called as synchronizing. In this post we shall be discussing some of the advantages of
the parallel operation of alternators.
1.

Continuity of Supply and Maintenance: This kind of connection is quite feasible when the repair and
periodical maintenance work is concerned. It is easier for maintenance when smaller individual generating units are
used, since we can schedule the maintenance of each unit one after the other without affecting the continuity of power
generation. While if we are using a single unit then the whole system has to be shut down for its maintenance work, this
would definitely affect the power demand during that duration.

2.

Efficiency: You might have seen the efficiency versus load current curve of the generator, according to that
the generator unit must run on full load, since efficiency is maximum when the load is 100%. So if we are using a single
large unit then it is uneconomical to use it on lower loads. While if we use smaller individual units we can add up or
switch off the generator units as per the load requirements in order to meet the maximum efficiency.

3.

Expansion Plans: Suppose the current capacity of the power plant is 500 MW, if after 2 year it plans to expand the
capacity to 700 MW then it will be much costlier to replace the whole single generator setup and to buy a bigger unit.
Rather it is economical to buy small individual alternator units which can be added in parallel to the bus bar system in
order to reduce the initial capital investment.

4.

Size of Alternators: More the rating of the generator, huge is the size of the setup. It is very difficult to manage a single
large alternator which may range around 1000 MVA or more. Rather if we are using small individual units connected in
parallel, it will be easier to manage considering its size.