Turbogenerator -An Introduction

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Index
1. Historical developments 2. Types of Generator

3. Main parts of Turbogenerator & its functions

4. New developments in Turbogeneartors

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Development of TG
Global development First single phase generator of 75 KW 1888 First 3 phase generator, salient pole 1900 First turbo type 3 phase 25 MW generator 1912 CEA, UK made 50 HZ as standard frequency for Europe 1925 First Hydrogen cooled 3 phase 30 MW generator 1937 First Hydrogen cooled TG with direct cooling of rotor 1949 First generator with water cooled stator winding 1956 First generator with water cooling for stator and rotor wdg1959

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Development of TG
In India
THREE PLANTS SET UP: IN 1950s:
At Bhopal with British collaboration 30 MW & 120 MW Hydrogen Cooled

IN 1960s: At Hardwar with Russian Collaboration 100 MW Hydrogen Cooled & 200 MW Hydrogen Cooled IN 1960s: At Hyderabad with CZECH Collaboration 60 MW Air Cooled & 110 MW Hydrogen Cooled

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Types of Turbogenerator
Generator Modules :Air Cooled Turbogenerator - TARI Hydrogen Cooled Turbogenerator - THRI Hydrogen/Water Cooled TG - THDF and THW

Module Nomenclature THRI 108/44 THDF 115/59

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Generator cooling System

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Stator Slot - TARI / THRI

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Stator Slot - THDF 500 MW

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210/235 MW THW Generator

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Capability of Generator Modules

DESIGN VARIANT GENERATOR MODULE TARI 93/38 TARI 108/36 TARI 108/41 TARI 108/46 THRI 93/38 THRI 108/39 THRI 108/44 THRI 108/44 B THRI 108/55 THW-200-2 THW-210-2 THW-235-2 THDF 115/59 THDF 115/55 OUTPUT RANGE 75-92 MW 100-120 MW 120-140 MW 140-170 MW 120-150 MW 210 MW 200-260 MW 260-275 MW 350 MW UPTO 200 MW 200-219 MW 220-237 MW 500-585 MW 500 MW(new)

AIR COOLED

HYDROGEN COOLED

HYDROGEN/WATER COOLED

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Capability of Generator Modules

125/67

800

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Library of Designs
1000 MW
WATER COOLED STATOR

350 MW
HYDROGEN COOLED

660 MW

170 MW
AIR COOLED
DESIRED MW CAPACITIES

80 MW

1000 MW

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THRI Generators - Design features

DIRECT HYDROGEN COOLING OF STATOR CORE AND ROTOR
WINDING INDIRECT COOLING OF STATOR WINDING EXPLOSION PROOF SINGLE PIECE STATOR FRAME END SHIELD MOUNTED BEARINGS VPI INSULATION SYSTEM TOP RIPPLE SPRINGS IN STATOR SLOTS TO CONTAIN BAR BOUNCING FORCES COLD GAS TEMPERATURE CONTROL VALVE TO MAINTAIN COLD GAS TEMPERATURE CONSTANT RING TYPE SHAFT SEALS STATIC/BRUSHLESS EXCITATION SYSTEM

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THDF Generators - Design features

DIRECT WATER COOLING OF STATOR WINDING AND
DIRECT AXIAL HYDROGEN COOLING OF ROTOR WINDING OPTIMALLY DESIGNED LEAF SPRING SUPPORT FOR CORE END SHIELD MOUNTED BEARINGS VPI INSULATION SYSTEM MASSIVE SUPPORT RING FOR STATOR WINDING OVERHANG TO ABSORB SHORT CIRCUIT FORCES SIDE AND TOP RIPPLE SPRINGS IN STATOR SLOTS TO CONTAIN BAR BOUNCING FORCES 5 STAGE AXIAL COMPRESSOR AND VERTICAL HYDROGEN COOLERS ON TURBINE END COLD GAS AND PRIMARY WATER TEMPERATURE CONTROL VALVES TO MAINTAIN AVERAGE INLET COOLING MEDIUM TEMPERATURES CONSTANT DOUBLE FLOW RING TYPE SHAFT SEALS BRUSHLESS EXCITATION SYSTEM BHEL Hardwar

TARI Generators - Design features

# DIRECT COOLING OF STATOR CORE AND ROTOR WINDING # INDIRECT COOLING OF STATOR WINDING # HORIZONTALLY SPLIT CASING DESIGN FOR STATOR # VERTICALLY SIDE MOUNTED COOLERS IN A SEPARATE HOUSING # VPI INSULATION SYSTEM # SEPARATELY ASSEMBLED STATOR CORE AND WINDING FOR REDUCING THE MANUFACTURING CYCLE # STATIC/BRUSHLESS EXCITATION SYSTEM

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500 MW Generator on test bed

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Gas Turbine Generator-Faridabad

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THRI 108/39 Stator with End Shield & Terminal box

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Main Parts of Turbogenerator

1. Stator - Stator Frame (Fabrication & Machining) 2. Core Assembly - Stator Core, Core Suspension Arrangement 3. End Shield

4. Stator Winding Assembly - Stator Winding , Winding Assembly,

Connecting Bus bar 5. Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor,

Rotor Assembly
6. Completing Assembly - Bearing Assembly, Shaft Seal Assembly, Oil Catchers, Insert Cover etc 7. Exciter 8. Auxiliary System BHEL Hardwar

Main Parts of Turbogenerator

Stator Core Cooler Insert Cover Rotor fan

End Shield

Wdg Overhang
Oil Catcher Rotor

Bearing Shaft Seal

Stator

Terminal Bushing

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Main Parts of Turbogenerator

Coolers

Foundation

Terminal bushing

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Ventilation Circuit in THRI TG

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Ventilation Circuit in THRI TG

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Stator Frame
Rigid fabricated cylindrical frame Withstands weight of core & wdg, forces & torques during operation Natural frequency away from exciting frequencies Provision for H2/CO2 filling Provision for temp measurements

Foot plates for supporting on foundation

provision for H2 coolers

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Stator Frame (500 MW)

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Stator Frame (Fabrication & Machining)

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Hydraulic/Pneumatic testing of Stator

TURBINE SIDE END SHIELD STATOR EXCITER SIDE END SHIELD

TEST PRESSURE= 10 BAR FOR

30 MIN

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Stator Frame (Air Cooled TG)

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Stator Core
Made up of punched segments of thin sheets of ETS Punchings coated by insulating varnish Vent segments at designed intervals for flow of cooling gas Compressed with tension bolts, pressure plate and clamping fingers Stepped arrangement at the end for reduction in eddy current losses

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Core Suspension - THRI/THW TG

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Core Suspension - 500 MW

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Core Suspension - Air Cooled TG

Location for Spring Core Housing

Core End Plate

Core

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End Shield
Closes both ends of Stator Frame Fabricated rigid box type structure in two parts Supports and houses bearings Provision for mounting Shaft seal body, Oil catchers, etc Provision for supply of Bearing Oil, Seal oil, Thrust oil and its drain

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End Shield - THRI TG

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End Shield (Exciter side 500 MW)

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End Shield (Turbine side 500 MW)

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Bearing Assembly

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Terminal Bushing Box 500 MW

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New dev - Total Impregnated generator

A VOID FREE HIGH VOLTAGE INSULATION ALON G THE ENTIRE LENGTH OF THE BAR A MECHANICALY FIRM BOUND BETWEEN ALL WINDING COMPONENTS AND THE INNER FRAME AND CORE BETTER SUITABILITY AGAINST THERMAL STRESSES DURING OPERATION BETTER HEAT TRANSFER LESS INSULATION THICKNESS - SPACE OPTIMIZED MACHINE LIFE IMPROVES INCREASE IN GENERATOR EFFICIENCY INCREASE IN SHORT CIRCUIT RATIO

INCREASE IN LINE CHARGING CAPABILITY

REDUCTION IN SPARES INVENTORY - STATOR BARS AND STATOR NO MORE REQUIRED AS SPARES REDUCTION IN OVERHAULING REQUIREMENTS : STATOR WEDGE TIGHTNESS CHECKING NOT REQUIRED SLOT WEDGES ARE

LOOSENING OF CORE AND FASTNERS REDUCED

GLUE INJECTION NOT REQUIRED ROTOR WITHDRAWL DURING INITIAL INSPECTION NOT REQUIRED

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WOUND STATOR CORE BEING LOADED FOR TOTAL IMPREGNATION

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CURING OF TOTALLY IMPREGNATED WOUND CORE

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INSERTION OF IMPREGNATED WOUND CORE IN STATOR

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Core Insertion into Stator

Activities :Measurement of dimensions for alignment of Stator & Core

Welding of Springs into Stator Placement of Impreg. Wound Core on C-Beam for deflection Placement of Wound Core on C-Beam with packing Insertion of Stator Frame over Core with the help of Crane Alignment of Stator with reference to Core Welding of Bush with Spring and Core Housing Rechecking of alignment dimensions

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Meas. Of Controlling dimensions

Stator

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Welding of Springs

Supports in the middle of Spring

L-Supports at the end of Spring

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Welding of Springs

Supports for bottom Spring

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Placement of Wound Core on C-Beam

Wound Core being placed on C-Beam

Wound Core on C-Beam

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Insertion of Stator over Core

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Welding of Bush with Spring & Core Housing

Alignment Bolt

Bush in position

Sealing during Welding

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THANK YOU

END

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