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Introduction
Kato Engineering primarily manufactures synchronous 3 phase electrical generators. The ability to predict
the subtransient reactance of a particular generator design is of prime importance. Power system designers
routinely use the generator subtransient reactance as a key parameter to aid in the design of the complete
electrical power generation system.
The subtransient reactance, X”d, is the generator internal impedance element that is effective in the first
cycles of a transient load event and determines the magnitude of the instantaneous fault current from the
generator. The transient reactance, X’d, becomes effective after approximately 6 cycles into a transient
load event and determines the amount of voltage change seen at the generator terminals due to the step
change in load. As stated, the reactances of a generator have a direct effect on the transient fault currents
experienced in an electrical power generation system, as well as the motor starting capability of the
generator. The magnitudes of the fault currents need to be calculated so that breakers, etc. can be sized
accordingly. The peak magnitudes of the 3 phase fault currents are inversely proportional to the
subtransient reactance of the generator. For new generator designs, the transient and subtransient
reactances are routinely tested for as part of a thorough evaluation of the generator’s performance
characteristics.
Traditional reactance prediction methods have served engineers well when new designs closely mimic
previous designs which have been tested and their reactance predictions validated. From the perspective of
the machine designer, an uncomfortable level of uncertainty always accompanied a new design that
deviated significantly from standard form. In this paper, a method is presented to calculate the transient
and subtransient reactance of a generator using transient dynamic circuit-coupled finite element
electromagnetic analyses. Finite Element electromagnetic analysis offers a powerful tool to reduce the risk
in new generator design.
A series of Finite Element (FE) electromagnetic simulations were performed in order to generate the
following simulation data:
• Open-Circuit Saturation Curve
• Generator Voltage Signal Harmonics
• Generator Transient and Subtransient Reactance
The open-circuit saturation curve and voltage signal harmonics were obtained from the magnetostatic
model and the reactance calculations were based upon results from a transient circuit-coupled model with a
moving interface at the rotor-stator air gap. The voltage signal harmonics were also calculated with the
transient circuit-coupled model, for comparison. The transient circuit-coupled finite element modeling
technique presented utilizes odd periodic symmetry along with a ‘moving’ interface at the rotor-stator air
gap. The use of odd periodic symmetry allows for the simulations to be accomplished with half of the
model size as compared to even periodic symmetry.
The particular generator design used for these analyses is a Kato Engineering, salient pole, 3 phase, 60 Hz,
13.8 kV synchronous generator. The generator rotor is a 4-pole rotor with a normal operating speed of
1800 RPM. The generator is rated for 4.5 MW of output power at 0.8 Power Factor with a temperature rise
of 95ºC at an ambient temperature of 50ºC. The generator is approximately 7 ft wide by 10 ft tall by 11 ft
long. Figure 1 shows a view of the generator assembly. One of the reasons this design was chosen for
analysis was the fact there is a plethora of good test data in existence for this design.
Model Information
For all of the simulations performed, the portion of the generator assembly modeled is commonly referred
to as the ‘active’ region of the generator rotor and stator. The ‘active’ region is comprised of the generator
rotor and stator ‘stacks’ along with their respective windings. The models are all 2D models with periodic
symmetry. The model covers 1 pole of a 4 pole generator (i.e. 90 degrees). The rotor shaft is included in
the rotor portion of the model, and the stator portion of the model is bounded by the outer diameter of the
laminated stator stack. Figure 2 shows a view of the 2D geometry which was utilized for all of the
simulations. The geometry was created in Pro/Engineer and transferred to ANSYS via an IGES file
transfer. The simulated ‘length’ of the model was 33.5 inches. This is representative of the stack lengths
for the rotor and stator.
Elements
Three basic element types were used in the models. The table below shows the element types that were
used and a general description of where they were used in the models
The same element mesh was used for the magnetostatic model and the circuit-coupled models. The mesh
contained 9,636 elements and 29,564 nodes (excluding the circuit elements and nodes). Figure 4 shows a
view of the element mesh (excluding the circuit elements). The mesh is not connected at a boundary arc
between the rotor and stator elements. The boundary arc resides at the middle of the ‘air-gap’ between the
rotor and stator.
Material Properties
For all of the simulations there were 3 unique magnetic materials, each with their own B-H curve. Figure 5
shows the B-H curves for the magnetic materials listed below:
• Rotor laminations – 16 Gage ASTM A715 Grade 80
• Stator laminations – 26 Gage M27 C3 (adjusted)
• Rotor shaft – AISI 1045 steel
Figure 5. Simulation B-H curves
The B-H curve for the stator laminations was adjusted from the vendor material property data in order to
account for the fact the stator core is vented. For this design the stator core has (12) integral vents. The
vents have an axial width of 0.375 inches. Therefore, over the active stack length of the machine (33.5”)
the stator core only has 29” of active lamination material in the axial direction. The fraction of the stack
length which is comprised of stator lamination material is 0.8657 (29/33.5). The actual stator lamination
flux densities in reality are 1.155x those calculated from the 2D model (1/0.8657 = 1.155). The B-H curve
of the stator lamination material is adjusted so that the correct magnetic induction (H) is required in order
to produce the flux densities which would be seen in reality. The mathematical B-H curve adjustment is
based solely upon the fraction of stator stack length active material (i.e. 0.8657). The open-circuit
saturation curve from the magnetostatic model was developed with and without the ‘stator vent correction’
in order to see how the stator vent correction affects the results.
The air regions, rotor and stator winding regions, stator slot stick regions, and damper cage element regions
of the model were all assumed to have a relative magnetic permeability of 1.0.
For the circuit-coupled models, the winding resistances for the circuit coupled winding elements were taken
from one of our in-house generator spreadsheet design programs. The program calculates expected
winding resistances based upon the design input parameters of the generator. The calculated cold winding
resistances were used because the generator reactance test is normally conducted on a ‘cold’ generator.
The ‘fill factors’ of the rotor and stator coils were back-calculated based on the given winding resistance,
winding length, number of turns, geometric area, and cold resistivity in order that the ANSYS calculated
winding resistances match the specified winding resistances from the Kato Engineering in-house design
program. The equation used by ANSYS for winding resistance based upon fill factor, number of turns,
geometric area, length, and resistivity is shown below:
ρ × L × turns × FF
R=
area
The circuit-coupled solid conductor elements, which represent the damper bars of the generator rotor, used
the cold resistivity of copper in the solid conductor element specification.
The no-load voltage signal harmonics can also be calculated from the transient open-circuit simulation
results by performing a Fast Fourier Transform directly on the simulation output voltage signal. The
individual harmonic magnitudes from the FFT are once again normalized by the fundamental harmonic
magnitude and the THD is calculated in the same manner as explained above. Figure 9 shows the transient
open-circuit simulation output voltage signals.
Figure 9. Transient Simulation Open-Circuit Voltage
Figure 10 shows a tabular comparison of the no-load line to neutral (L-N) phase voltage signal harmonics
from the simulation predictions and from the actual test data voltage signal harmonics measured in the
generator FAT. The predicted peak individual harmonic was 0.99% and 1.03% for the 5th harmonic from
the magnetostatic and transient simulations, respectively. The peak individual harmonic from the generator
test data was 0.94% for the 5th harmonic. The predicted total harmonic distortion (THD) was 1.336% and
1.490% from the magnetostatic and transient simulations, respectively. The THD from the generator test
data was 1.340%. The R&D spreadsheet program predicted a peak individual harmonic of 1.105% and a
THD of 1.431%.
Figure 10. Generator Voltage Harmonics Comparison
Conclusions
The open-circuit saturation curve predicted from the magnetostatic simulation correlates extremely well
with the open-circuit saturation curve developed from the generator Factory Acceptance Tests. The
predicted field current required to produce rated open-circuit voltage was within 0.5% of the actual tested
field current requirement. The model does an excellent job of predicting the saturation characteristics of
the machine and this capability has proven to be extremely useful. The heating in the field coil winding is
proportional to the square of the current flowing in the winding, and the ability to accurately predict the
current requirements has a big impact on the ability to predict the heat generation in the field coil windings,
among other things. Our in-house spreadsheet design programs generally do a good job of predicting the
linear behavior of the saturation curve (i.e. the air-gap line), but they tend to struggle with the actual
saturation characteristics as well as the effects of the air vents in the stator stack. The excellent correlation
of the FE model saturation curve essentially validates the magnetic material properties used for the
analyses.
The magnetostatic model and transient circuit-coupled model both do a good job of predicting the voltage
signal harmonics for the generator. In this case, the predictions from the magnetostatic model were the
most accurate. The peak individual harmonic prediction from the magnetostatic model was within 5.3% of
the measured peak individual harmonic from the generator Factory Acceptance Tests. The Total Harmonic
Distortion prediction from the magnetostatic model was within 0.3% of the measured Total Harmonic
Distortion. The R&D in-house spreadsheet design program also does a reasonably good job of predicting
the voltage signal harmonics. The spreadsheet predictions were within 17.6% and 6.8% for the peak
individual harmonic and Total Harmonic Distortion, respectively. Note that the simulations show a higher
harmonic distortion content near the 30th harmonic than what is found in the test data. For this generator
design, the slot passing frequency for the rotor is 1.8 kHz. The 30th harmonic has a frequency of 1.8 kHz.
The simulation voltage signal has a 1.8 kHz ripple due to the rotor passing the stator slots. This is typically
reduced in reality by using a slot skew on the stator stack. This particular design has a 1 slot skew and the
skew results in lesser measured distortion near the 30th harmonic.
The transient circuit-coupled simulation provides a powerful tool for predicting the transient and
subtransient reactances of the generator. The subtransient reactance prediction was within 5.5% of the
measured value from the generator Factory Acceptance Tests. The transient reactance prediction was
within 10.7% of the measured value. The reactance calculations themselves are a bit nebulous due to the
nature of how the calculations are carried out. Typically, Kato Engineering guarantees the measured
reactance values within +/-20% of the predicted reactance values. The importance of the ability to predict
the reactance values can be brought to light by considering the history of this particular generator design.
The guaranteed subtransient reactance for this generator design was 9.3% to 12.6% (+/-15% of the standard
spreadsheet design program prediction). This particular customer specification had a slightly narrower
tolerance band for the allowable subtransient reactance (i.e. +/-15%). The measured subtransient reactance
was 9.1% and we had to request a specification deviation from the customer in order to deliver the
generator. Had we been able to use the Finite Element simulation tools presented herein for predicting the
subtransient reactance we would have put forth a guaranteed range of 7.3% to 9.9%, and the measured
subtransient reactance would have been well within the limits of our customer driven specification.
References
1. John H. Kuhlmann, “Design of Electrical Apparatus”, 3rd ed., John Wiley and Sons, New York,
1950.
2. James W. Nillson, “Electric Circuits”, 4th ed., Addison-Wesley Publishing Company, 1993.