POWER

POWER PRODUCTION CONSUMER

POWER

TURBINE COMPRESSORS

GENERATOR

THERMAL GAS STATOR ROTAR EXICITER CONDENSORS COMPRESSORS

PIPE

POWER GENERATION.

POWER TRANSMISION STEPUP POWER DISTRIBUTION

STEP DOWN

COUSTOMERS USE

BULB FAN COOLERS IRONBOX TAPES FACTORIES etc

GENERATOR

STATOR EXCITER

ROTOR

CORE RTD WINDING WINDING YOKE ARMATURE

FORGING

TESTING PROCESS MANUFACTURE PERFORMANCE ASSEMBLING

GENERATOR PRODUCTION

READY FOR

. . INTRODUCTION It is a well-known fact that all power plants are located in such a place where there are lots of resources. For example THERMAL POWER PLANTS near coal resources, HYDRALPOWER PLANT where there is lot of water is present.

As we all know that in KOTHAGUDAM we have we have one THERMAL power plant. There we have TURBINES, BIOLERS, COMPRESSORS,

CONDENSERS and GENERATORS. We need all these Machines to produce POWER.

We need coal to produce steam, Steam helps to rotate the turbine, turbine will be rotating the shaft of the rotator and in turn exciter is also been rotated to produce power. Boiler is used to produce steam for rotating turbine

GENERATOR

TURBO GENERATOR The Generator components: STATOR Stator Frame, Stator Core, Stator Winding, Generator Coolers, Stator End Covers. ROTOR Rotor shaft, consists of the following

Rotor winding, Rotor Retaining Ring, Field Connections. EXCITER Design features, Rectifier wheels, Field Connections. BEARINGS SKID TESTING PROCESS During manufacturing process, During Assembling, Performance test. BREAKERS

NOTES ON GENERATOR INTRODUCTION Types of Generators GENERATOR BEARINGS The generator rotor is supported at two journal bearings. The bearings consist of a bearing pedestal and bearing shell is split into two halves to facilitate assembly. The bearing pedestals are iron castings and the bearing shells are steel castings. The bearing pedestal is provided with a spherical seating surface and the bearing shell rests in it with its outer spherical surface. The inner surface of bearing shell is provided with spiral grooves and cast with Babbitt metal. Bearing Oil Supply: The oil required for bearing lubrication and cooling is obtained from the turbine oil supply system and supplied to the lubricating groove in the bottom-bearing sleeve. The upper bearing sleeve consists of a wide over flow

groove through which oil is distributed over the shaft journal and fed to the lubricating gap. Bearing Temperatures: The temperature of each bearing is monitored by one double-element RTD. The RTD is screwed in position on side of the lower bearing sleeve from outside with the detector extending to the Babbitt liner.

STATOR INTRODUCTION: Stator frame is of welded construction, supports the core and the windings. It consists of air duct pipes and radial ribs, which provide rigidity to the frame. Footings are provided to support the stator on the skid. The stator frame should be rigid due to the various forces and torques during operation. The welded stator frame consists of two end plates, axial and radial ribs. The arrangement and dimensioning of the ribs are determined by the cooling air passages, the required mechanical strength and stiffness. The end covers are aluminium alloy castings. The stator frame is fixed to the skid with the help of hexagonal bolts. The skid is interim fixed to the concrete foundation through foundation bolts. Stator core:

The core packed into the stacking frame is pressed firmly together between the end plates of the machine frame and fixed in this position by welding the axial ribs of the core and the end plates of the frame. End fingers on the inside diameter of the end plates transmit the pressure to the teeth of the core. The compressive force produced prevents the laminations and teeth from vibrating. An eye is welded to each end plate for attaching suitable lifting gear with adequate lifting capacity for transporting the complete machine. All the forces that occur during normal operation or on short circuits are transmitted from the stator yoke to the base frame via the seating plates and into the foundation.

Location of Bars: A semi-conducting wrapper of graphite paper in the slot protects the bar. The stator winding is protected against the effects of current forces in the slot section. To ensure tight seating of the bar at the slot bottom, a slot bottom-equalizing inserted. A top strip ripple of press is path is spring arranged

between two compression strips to exert a continuous pressure on the bars. The bars are shaped so that, cone shaped end windings are obtained. In order to reduce the stray losses a small cone taper of (13-20) is used. On the wide sides of the bars spacers of insulating material are inserted at regular intervals. Bearings : The rotor runs in two floating type guide bearings, designed as pedestal bearings, with forced oil or oilring lubrication. The driven end bearing is secured to the base frame and insulated from the latter. As the

connections are designed to prevent short-circuiting of the insulation. Enclosure : The enclosure consists of the inner and outer components. The inner components comprises of the winding covers, which form an angular enclosure of the overhang of the stator winding and are also used as air ventilator rings. The outer enclosure consists of top and bottom parts and is designed as required for the particular degree of protection, as indicated in the dimension drawing or in Technical data. The ventilating circuit is of the double - ended symmetrical arrangement.

STATOR CORE: Stator core is stacked from insulated electrical sheet laminations and suspended in the stator frame from

insulated dovetailed guide bars. Axial compression is obtained from clamping fingers, clamping plates and non-magnetic clamping bolts which are insulated from the core. In order to minimize the hysterics and eddy current losses of the rotating magnetic flux which interacts with the core. The entire core is built up of laminations, each layer of which is made from a number of individual segments. The segments are punched from silicon steel. In the outer circumference the segments are stacked in insulated trapezoidal guide bars, which hold them in position. The guide bar is not insulated to provide for grounding the core. The laminations are hydraulically compressed and heated during the stacking procedure. The complete stack is kept under pressure and fixed in the frame by means of cell

STATOR Stator frame is of welded construction, supports the core and the windings. It consists of air duct pipes and radial ribs, which provide rigidity to the frame. STATOR Stator frame is of welded construction, supports the core and the windings .It consists of air duct pipes and radial ribs, which provide rigidity to the frame. Footings are provided to support the stator on the skid. The stator frame should be rigid due to the various forces and torques during operation. The welded stator frame consists of two end plates, axial and radial ribs. The arrangement and dimensioning of the ribs are determined by the cooling air passages, the required mechanical strength and stiffness. The end covers are aluminium alloy castings. The stator frame is fixed to the skid with the help of hexagonal bolts. The skid is interim fixed to the concrete foundation through foundation bolts. Electrical Connection of Bars and Phase Connections:

Brazing makes Electrical Connection of Bars: Electrical connection between the top and bottom bars, one top bar being brazed to associated bottom bar. The coil connections are wrapped with tapes. The thickness of the wrapper depends on the machine voltage. After taping, 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 tape, which contain synthetic resin having very good penetration properties. The phase connections 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 the 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 out through insulating plates. ROTOR Introduction: ROTOR WINDING Construction: The field winding consists of several series connected coils inserted into the longitudinal slots of the rotor body. The coils are wound so those two poles are obtained. The solid conductors have a rectangular cross-section and are provided with axial slots for radial discharge of the cooling gas. The individual conductors are bent to obtain half turns. After insertion into the rotor slots, these turns are combined to form full turns of series connected turns of one slot constituting one coil. The individual coils of the rotor winding are electrically series connected so that one north and one south magnetic pole are obtained. Insulation:

The insulation between the individual turns is made of layers of glass fiber laminate. The coils are insulated from the rotor body with L shaped strips of glass fiber laminate with Nomex interlinear. The strips are provided with axial slot of the same cross- section and spacing as used on the rotor windings. Rotor Slot Wedges: To protect the winding against the effects of the centrifugal force, the winding is secured in the slots with wedges. The slot wedges are made from an alloy of high strength and good electrical conductivity, and are also used as damper wedged bars. The retaining rings act as short circuit rings to induced currents in the damper windings. ROTOR SHAFT: The rotor shaft is forged from a vacuum cast steel ingot. The high mechanical stresses resulting from the centrifugal forces and short circuit torques call for high quality heat-treated steel. The rotor consists of an

electrically

active

portion

and

two

shaft

ends.

Approximately 60% of the rotor body circumference has longitudinal slots, which hold the field winding. Slot pitch is selected so that 180 displace the two solid poles. The rotor wedges act as damper winding within the range of the winding slots. The rotor teeth at the ends are provided with axial and radial holes, enabling the cooling gas to be discharged into the air gap after, intensive cooling of the end windings. 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 though radial

openings in the conductors and in the rotor slot wages. The cooling air for the end winding is drawn from below the rotor-retaining ring. It rises radically along the individual coils and is then discharged into the air gap via axial and radial slots in the end portions of the rotor teeth. Direct Cooling: Usually use in the rotor to eliminate hotspots adjacent mechanical conductors. Indirect Cooling: Used for stator windings. and differential temperatures would in the between result in copper components, stress which

particularly

AIR COOLING CIRCUIT: Air is circulated using two axial flow fans arranged in the rotor shaft. The fans draw cold air from the cooler unit, which is divided, into 3 flow paths. 1. It is directed into rotor end winding space. Part of it also flows over the individual coils for cooling in the rotor end winding and then leaves the end windings via the bores in the rotor teeth. Other part flows from the rotor end winding space into slot bottom ducts. From this it will discharge into the air gap via radial ventilating ducts. 2. Air is directed over stator end windings to the air ducts into the space between the generator housing and the stator core. Then air flows into the ventilating slot of the stator core, where it absorbs heat from the stator core and stator windings.

3.

It is circulated into the air gap via the rotorretaining ring. The air then mixes with the hot air flowing via ventilating ducts in the stator core into the outer hot air compartment in the stator frame for being returned to the cooler. The three flow paths in the air gap and hot air is returned to the cooler via hot air ducts for recooling and drawn again by the fans.

ROTOR WINDING Construction: The field winding consists of several series connected coils inserted into the longitudinal slots of the rotor body. The coils are wound so those two poles are obtained. The solid conductors have a rectangular cross-section and are provided with axial slots for radial discharge of the cooling gas. The individual conductors are bent to obtain half turns. After insertion into the rotor slots, these turns are combined to form full turns of series connected turns of one slot constituting one coil. The individual coils of the rotor winding are electrically series connected so that one north and one south magnetic pole are obtained. Insulation: The insulation between the individual turns is made of layers of glass fiber laminate. The coils are insulated from the rotor body with L shaped strips of glass fiber laminate with Nomex interlinear. The strips

are provided with axial slot of the same cross- section and spacing as used on the rotor windings. Rotor Slot Wedges: To protect the winding against the effects of the centrifugal force, the winding is secured in the slots with wedges. The slot wedges are made from an alloy of high strength and good electrical conductivity, and are also used as damper wedged bars. The retaining rings act as short circuit rings to induced currents in the damper windings.

ROTOR RETAINING RING: 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 windings without contact on the shaft. The shrunk on hub at the free end of the retaining ring 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 silvered plated, ensuring a low contact resistance for induced current. To reduce the stray losses and have high strength, the rings are made of non-magnetic, cold worked materials. FIELD CONNECTIONS: The field connections provide the electrical connection between the rotor winding and the exciter. Terminal Lug: 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 in the shaft bore. ROTOR FAN: The generator cooling air circulated by two axial flow fans located on the rotor shaft one at either end. To augment the cooling of the rotor winding the pressure established by the fan works in conjunction with the air expelled from the discharge ports along the rotor. The blades of the fan have threaded roots for being screwed into the rotor shaft. The blades are forged from an aluminum alloy. Threaded root fastening permits the blade angle to be changed. TEST PROCEDURES Mechanical run and measurement of vibrations at rated speed: This test is run after assembly of machine on test bed. Equipment for running test:

D.C motor drives system. Bearing lubricating system Cooling water system. Current transformers - 2 nos. Potential transformers - 2nos. D.C current shunts - 2 nos. A.C volt meters - 3nos. DC millivolt meters - 2 nos. Phase sequence indicator. Multi meter for continuity checks. Vibration monitor. RTDs temperature monitor. 50 Hz A.C High voltage test equipment. Meggers Micro ohm meter. Connecting leads and earthing cables. The turbo-generator under test is assembled

separately with out coolers and enclosures (if any), on

a test foundation frame using it's own bearings and coupled to a calibrated D.C. drive motor with gearbox of suitable capacity (1900 kw /1300/290 kw). The generators, which have brush less excitation system, are tested with additional test pit slip rind shaft. The power to the drive motor and the field of the generator are drawn independently from the Thyristor connectors / Ward - Leonard sets situated in electrical machine rooms and controlled from test gallery. The machine is rolled and run at rated speed after ensuring the bearing oil, and kept at rated speed for stabilization of bearing temperatures. The vibrations are measured at rated speed on both the bearings housings (pedestals) in Horizontal, vertical and Axial directions with the help of vibrating meters which is internally connected to the monitor and the vibrations are noted in the form of graphs. The temperature of stator is monitored by RTDs / Thermocouples embedded in winding, core and tooth.

Measurement of mechanical losses, short circuit characteristic and losses: The machine is prepared for short circuit

characteristics using current transformers and shorting links. 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%, 30%, 40%, 50%. At each step the following parameters are noted.

Stator current (Ia and Ib) Rotor current corresponding to stator current (If). Drive motor voltage and current corresponding to stator current (Vd & Id)

Bearing vibrations at rated stator current. RTD readings at rated stator current. The excitation is reduced and cut off. The speed is reduced and the machine is cooled at lower speed. The temperatures are checked from RTDs. The machine is stopped when it is sufficiently cooled down.

From above data, the characteristic curves are plotted as follows % In v/s If. % In v/s m/c losses in kw. (Fig 6 sample of m/c losses curves) xerox 11 output = output +total losses Field current at 100% En from OCC S.C.R = Field current at 100% In from SCC

% Efficiency of TG 100

Measurement of mechanical losses, open circuit characteristic and losses. The machine is prepared for open circuit

characteristic. The machine is run at rated speed and drive motor in put voltage and current are noted and m/c is

excited

gradually

in

steps,

at

20%,30%,40%,50%,60%,80%,95%,100%,105%,110 %,115%,120%,125%130% At each step the following parameters are noted.

Stator voltages (Vab,Vbc, & Vca) Rotor current corresponding to stator voltage (If) Drive motor voltage and current corresponding to stator voltage. (Vc & Id)

At 95% En following parameters are noted. 4. Shaft voltage. 5. Checking of phase sequence. 6. Bearing vibrations at rated stator voltage. 7. RTD readings at rated stator voltage. The excitation is reduced and cut off. The speed is reduced and the machine is cooled at lower speed. The temperatures are checked from m/c RTDs. The m/c is stopped when it is sufficiently cooled down.

From the above data, characteristic curves are plotted as follows % En v/s If. % En v/s m/c losses in kw. Measurement of Shaft voltage: Shaft 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 O.C. condition at 100% Checking of Phase sequence: Phase sequence of generator is checked using a phase sequence indicator across PT output terminals when m/c is in OC. Condition at 100%. Measurement of rotor impedance. Equipment

50 Hz (Power frequency) A.C source. A.C.Voltmeter. A.C.Ammeter Multimeter for continuity checks. Current trasformer (50 / 5A OR 100 / 5A) Connecting leads.

Rotor impedance is measured at standstill and at rated speed of the machine. Evaluation of Impedance: V Z Where V I Measurement Z : : of : = I Impedance in ohm

Voltage in Volts. Current in Amps. insulation resistances of rotor

windings before and after high voltage test.

Equipment: Motorized Megger (1000 V/ 2500 V) Earthing Rod & earthing cable. Insulation resistance of the rotor windings are measured before and after high voltage test using Megger of 1000 V for rotor windings. The values are taken at 15 sec. And at 60 sec. A absorption coefficient of insulation is found out as , IR at 60 " Absorption coefficient = IR at 15 " This value for H.V. test should be 1.5 The winding is discharged to earth after each measurement. High voltage test on rotor windings 50 Hz A.C High Voltage transformer and its Induction Regulator / Input autotransformer.

Potential transformer Volt meter Binding wire. Earthing rod & earthing cable. The m/c is prepared for High voltage test. When high voltage test is done on one phase, all other phases and rotor winding, instrumentation cables 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. The test is conducted on all the phases and rotor winding separately. High voltage levels: Rotor winding: (10.up) volts. With minimum of 1500v and maximum of 3500v.

Where, Up = Excitation voltage. Measurement of DC resistance of rotor windings in cold condition: Equipment's: Digital micro ohmmeter and it's measuring leads. Thermometer. DC resistances of rotor windings are measured separately using micro ohmmeter. Evaluation of resistances at 200 C is done by using formula: Rt . (235+20) R20 = (235+T) where, R20 = Resistance at 200 C in m T = average temperature of the rotor winding in Rt = measured resistance of winding in m
0

Measurement of D.C. resistances and insulation resistance of RTDs and /or thermocouples: The D.C. resistances and insulation resistances of RTDs / thermocouples are measured using multimeter and megger respectively and noted.

EXCITER Design 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 carries 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 assemblies results in coupling of the dc leads in the central shaft bore through the Multi contact 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 wafer of the diodes. One diode each is mounted in each light metal heat sink 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 R.C.block. The three-phase connection between armature and diodes is obtained via copper conductors arranged on the shaft circumference between the rectifier wheels and the main exciter. One conductor is

provided for each arm of Diode Bridge. The conductors originate at a bus ring system of the main exciter. Three-phase Pilot Exciter: The three-phase pilot exciter has a frame, which accommodates the laminated core with the threephase winding. The rotor consists of a hub with mounted poles. Each pole consists of separate permanent magnets, which are housed, in a nonmagnetic metallic enclosure. Three-phase Main Exciter: The three-phase main exciter is a six revolving armature unit, the frame poles with the field and damper winding. The field winding is arranged on the laminated magnetic poles. The rotor consists of stacked laminations, which are compressed by through bolts over compression rings. The three-phase winding is inserted in the slots of the laminated rotor. The winding conductors are transposed within the core length and the end turns of the winding are secured with steel bands. The winding ends are run to a 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. * Using a DC generator we have a problem of connections at high speeds like 3000 rpm, which is usually reduced to 1000 rpm with the help of gearbox. It is difficult to obtain commutation at this speed without sparks. In order to avoid this various brush less exciter is used whose circuit diagram is as follows: The generator rotor is supported at two journal bearings. The bearings consist of a bearing pedestal and bearing shell is split into two halves to facilitate assembly. The bearing pedestals are iron castings and the bearing shells are steel castings. The bearing pedestal is provided with a spherical seating surface and the bearing shell rests in it with its outer spherical surface. The inner surface of bearing shell is provided with spiral grooves and cast with Babbitt metal.

Bearing Oil Supply: The oil required for bearing lubrication and cooling is obtained from the turbine oil supply system and supplied to the lubricating groove in the bottom-bearing sleeve. The upper bearing sleeve consists of a wide over flow groove through which oil is distributed over the shaft journal and fed to the lubricating gap. Bearing Temperatures: The temperatures of each bearing are monitored by one double-element RTD. The RTD is screwed in position on side of the lower bearing sleeve from outside with the detector extending to the Babbitt liner. Exciters Test conducted in exciters Mechanical run and measurement of vibrations at rated speed. The machine is run to rated rpm after ensuring the bearing oil and kept at rated speed for stabilisation of bearing temperatures. The vibrations are measured on

both the bearing housing (pedestals) using vibration probes and vibration monitors in horizontal, vertical and axial directions. Drive motor input voltage and current are measured to evaluate losses. Open circuit characteristic: The machine is prepared for open circuit characteristic and a 500 resistance 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 field is excited gradually in suitable steps upto rated output voltage. At each step following parameters are noted: Va : out put voltage of exciter. If : field current of the exciter. Vq1,Vq2 : quadrature axis coil voltages, and Vd : Drive motor voltage. Id : drive motor current. and bearing vibrations.

Load magnetization characteristics and calibration of quadratic axis coils: The machine is prepared for load magnetization characteristics. A variable water load resistance is connected across the slip rings. The machine is run at rated speed, load breaker is closed and m/c is excited gradually. The following parameters are noted down in steps up to the rated current by adjusting load resistance to R40. The load resistance is maintained at R40 at all the steps by the adjusting the water load resistance. Measurement of DC Resistances of armature windings, main pole winding and quadrature axis coils: After dynamic tests the machine is allowed for cooling and when it is sufficiently cooled, the DC resistances of all the three armature windings, main pole winding and quadrature axis coil are measured separately by micro ohm meter. The ambient temperature is also recorded

and evaluation of resistances at 200 C is done by using the formula: Rt . (235 +20) R20 = ------------------ ( 235+t) R20 = D.C. resistance at 200 C T = temperature of the winding in 0 C Rt = DC resistance of the winding at 0 C Measurement of IR value and high voltage 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 winding. Rotor and stator bodies are properly earthed. IR values of the windings are measured with 500 or 1000 volts megger and values at 15" and 69" are noted before and after High voltage tests.

HV test is done on individual windings using high voltage test kit by regulating primary voltage to transformer. Slowly HV is reached and maintained for one minute and reduced to zero. The object is then discharged by earth rod and IR values are taken. When test is done on one winding, the other windings are earthed. Testing of permanent magnet generator The PMG is assembled along with Brush less Exciter on the test foundation frame. The output is connected to a three-phase resistance load (variable in steps). As PMG has got permanently magnetised field poles, it starts generating voltage right from start of mechanical run.

TESTING OF TURBO GENERATORS The various tests conducted on Turbo Generators are as follows: 1. 2. 3. 4. 5. Air leak test & determination of leakage per day. Mechanical run test in air medium. Bearing vibration measurements. Over hang winding and core vibration measurement at 2850, 3000 & 3150 rpm. Mechanical heat run test at rated speed (i.e. 3000 rpm) to determine the heat up as a result of Mechanical losses in Hydrogen medium. 6. 7. Noise level measurement with meter dB(A) at 3000 rpm. Three phase short circuit characteristic and losses measurement up to 110% In i.e. 11679.8A in steps at 20%, 40%, 60%, 80%, 100% and 110% In. 8. 9. IR value measurement of stator windings after S C C heat run test. Open circuit characteristic and losses measurement up to 120% En i.e. 12.6 KV in steps

at 20%, 40%, 60%, 80%, 90%, 95%, 100%, 105%, 110% & 120% En. 10. Shaft voltage measurement at 100% En. 11. Phase sequence and voltage balance checks. supply. 13. IR value measurement of the stator and rotor windings after hydrogen purging out. 14. Impedance measurement of Rotor at stand still, 1000, 2000 & 3000 rpm by 50 Hz ac supply at 5A, 10A (Voltage limited to generator terminals open circuited in air medium). 15. Impedance measurement of Rotor at stand still, 1000, 2000 & 3000 rpm by 50 Hz ac supply at 5A, 10A (Voltage limited to 250v) generator terminals short-circuited in air medium. 16. IR value measurement and high voltage (level : 1000 v) on Rotor winding at 3000 rpm. 12. Impedance measurement of rotor with 50Hz

Testing of Turbo Generators The are different types of TESTS are: 1. EXAMINATION OF THE ROTOR FORGINGS. 2. ROTOR COIL BINDING RING TEST. 3. HYDRAULIC TEST ON THE STATOR CASING. 4. CORE FLUX TEST. 5. ROTOR WINDING AND CELL INSULATION TESTS. 6. TESTS ON THE STATOR COIL. 7. BALANCING AND OVER SPEEDING OF THE ROTORS. LET US DISCUSS BRIEFLY ABOUT ALL THESE TESTS, 1. EXAMINATION OF THE ROTOR FORGINGS THE ROTOR, BEING THE MOST HIGHLY STRESTED PART OF THE TURBO GENERATOR, MUST BE PROVED THROUGHLY SOUND BEFORE IT IS PASSED INTO SERVICE. IT IS SUBJECTED TO A LARGE NUMBER OF RIGOROUS DYNAMIC

PHYSICAL, INSPECTION

OPTICAL TESTS.

AND THESE

ELETRICAL TESTS ARE

DESIGNED TO DETECT LIKELY FLAWS IN THE NMATERIAL, AS EARLY AS POSSIBLE. INTIAL tests are done at forging manufactures works. SPECIMEN PIECES ARE OUT FROM THE SHAFT AND ROTOR BODY AND SUBJECTED TO (A) TENSILE (B) BENDING (C) PREMEABILITY TESTS TO CHECK ITS CONFORMITY WITH THE SPECIFICATION. SULPHUR PRINTS ARE TAKEN AT SHAFT END AND ON ROTOR BODY FOR MICROSCOPIC EXAMINATION TO STUDY THE PRESENCE OF SULPHIDE. A SURFACE INSPECTION IS MADE AAFTER ROUGH MACHINING AT STEEL MAKERS WORKS. MAGNETIC TESTS ARE CONDUCTED TO DISCLOSE ANY HAIR CRACKS NOT VISUALLY DETECTABLE. THE PROCESS consists of magnetizing the forging

and exposing the surface under examination to a stream of paraffin carrying magnetically prepared particles finely divided the iron powder. under Fine the cracks are disclosed by a concentration of iron bridging cracks influence of the magnetic field. The rotor forging is bored along its axis and magnetic crack detection test carried out .the core of a rotor forging is trepanned and rough machined stage these tests detect sub surface unsoundness, cracks or non metallic inclusions. The services of specialist staff in metals section of Research and development division of H.E .are utilized for all the abovementioned tests. ROTOR COIL BINDING RING TESTS: These are the most highly stressed parts of the rotor, made of non magnetic austenitic

steel forging and warm worked by a special process called mandrel Expanding. To avoid local concentration of high stresses, ventilating or locating purposes. Specimen taken from ends of forging are subjected to tensile and bending tests. Crack detection: Magnetic of crack .the detection method technique is not effective because of the nonmagnetic materials rings adopted is dye-penetrating tests. The surfaces to be examined are machined to a smooth finish and are sprayed with a fine white powder, such as French chalk. The dye will appear on the chalk as clearly visible red lines against the white background if cracks are present. HYDRAULIC TESTS: Rings are subjected to hydraulic tests with oil under pressure, which induces stresses up to 65% of the yield point.

Hydraulic test on stator casing: sound top the extent pressure associated of with

the purpose

of this tests is to ensure that the frame is withstanding the explosion of a

mixture of air in hydrogenated also to check that all the welds are sound and free from leakage cracks .the test pressure of water for all hydrogen cooled stators is 70 l bs /inch2 irrespective pressure. of casing hour, hydrogen for six design the Every hours,

pressure is first increased to maximum value and then reduced to zero suddenly, thereby giving pressure impacts. Stator core Flux Test: Immediately after the core is built up and before it is wound, a test is made to detect the presence of local hot spot. Whenever there are shorts between adjacent core lamination s, due to break of inter laminar insulation or burrs on the edges, high eddy currents flow giving rise to

temperature rise in that zone. Several turns of cable are wound through the machine bore and out side frame. The winding is fed from a single-phase full working by variable flux voltage 50 to cycles rated core supply. The object is to set up in the core, the corresponding and voltage of the machine. Bad local heating is caused shorted burred laminations and may be detected after a short time by running the hand over the surface of the core. A is set of reading taken as on well core as thermocouples also

external contact thermometers are used to take temperature at other points of yoke and core. The remedy for such defects is to introduce further insulation between laminations and in all, but the worst cases; this may be done with out dismantling the core. Wattmeter the connected loss and to the by input indicates iron keeping

comprehensive records for every size and

type of machine, the readings obtained may be used to estimate the stator core loss in service. By intelligent analysis of the results a bad core with perhaps an excessive iron loss may be detected and remedied before it is wound. ROTOR WINDING AND CELL TESTS

BEFORE ASSEMBLY: The rotor coils and their insulation are subjected to high stress when in normal operation. Thus a through 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 wedges, which is cumbersome job. The rotor winding is subjected to a final shipping pressure test of 3.5 kV for one minute in case of 30 Mv and 120MW.

TESTS ON ROTOR SLOT CELLS: The epoxy impregnated glass cell forms ground insulation and for H.E.rotors, a voltage test of 10 KV for one minute is applied in the initial stage. Subsequent to the testing of the cell during various stages of assemble at reduced, the entire winding is finally subjected to a shipping test voltage of 3500 volts.

TESTS ON ROTOR COILS: TESTS ON ROTOR COILS: Test Between turns: The rotor coil sections are made up of a number of turns which are formed in halves and then assembled with their inter turn insulation and bonded with an adhesive in the steam heated press. Although normal working voltage per turn may be very small, a turnto-turn test of 240volts is done to exercise quality control. TOP TURN TROUGH: The insulation at 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 is applied for one minute to test the top through.

Test On Complete Rotor Winding:

After

placing the coil in the slots, before joining after jointing, fitting dampers and wedges and fitting coil binding rings connected to the collector rings up to run at speed, the graded high voltage tests are carried out at run. each stage, starting with down to shipping pressure test after over speed Shipping test on rotor is both in standstill and running condition. COLLECTOR LEADS: A high voltage

equivalent to the shipping test plus 1500 volts is applied to collector leads when fitted in bore with studs of seals fitted but before connecting to windings. TESTS ON STATOR COILS: As per the standards, the stator winding has to be subjected to shipping pressure test of (2 line volts +1KV). Incase of 30Mw and

120MW generator. In order that machine when wound withstands this final voltage test, and any faulty coil is eliminated during the various stages of coil manufacture and winding. Because the continued application of high voltage tests may over stress the winding insulation, the voltage is reduced at various stages. Test between parallel straps: This is a test of strap insulation provided for eddy E. M. F., a low voltage of the order of 350 volts for 3seconds is applied. COILS IN MANUFACTURE AND WINDING SECTIONS: When the coils are first tested, a voltage of 8 K V in excess of shipping pressure test is applied and this voltage tests are repeated.

TESTS Volts

ON

THERMOCOUPLES: test is applied to

1000 the

megger

thermocouples. BALANCING AND OVERSPEEDING 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 curves is taken sure those critical speeds of vibration amplitudes. The design makes sure that the critical speed is well away from the running speed. OVERSPEEDING: In order to check the soundness of all parts and fitting on rotor assembly, the rotor is run at an over speeding test house at Bhopal is one of the most modern in the world. Performance Tests

WORKS TESTS ON COMPLETED MECHINE: There are two types of tests they are: Routine tests Type test. ROUTINE TESTS ON TURBOGENERATOR 1.0. Scop This test procedure covers procedures for 0 e: Routine Tests on Turbo generators. 2.0. Tests conducted: 0 1. Mechanical run and measurement of vibrations 2. 3. 4. at rated speed. Measurement of mechanical losses, short circuit characteristic and losses. Measurement of mechanical losses, open circuit characteristic and losses. 5. Measurement of shaft voltage. 6. Checking of phase sequence. 7. Measurement of Rotor Impedance (rotor inside stator). 8. Measurement of insulation resistance of stator

9. & rotor windings before and after high voltage 10. test (m/c at rest). High Voltage test on stator and rotor windings 11. (m/c at rest). Measurement of Polarization Index of stator winding. Measurement of d.c. Resistance of stator & rotor windings in cold condition. Measurement of d.c. Resistance and insulation resistance of RTDs.

TYPE TESTS ON TURBOGENERATORS 1.0.0 Scope: This test procedure covers procedures for Type Tests on Turbo generators. 2.0.0 Tests conducted 1. Measurement of Capacitance of stator winding. 2. Measurement of Tan of sample coils of stator winding impregnated along with stator. 3. Heat run tests: a) Mechanical heat run test. b) Short circuit heat run test. c) Open circuit heat run test. 4. Voltage waveform analysis and determination of Telephone harmonic factor (THF). 5. Measurement of residual voltage of stator windings at rated speed. 6. Line to Line sustained short circuit test and determination of Negative sequence reactance (X2). 7. Line to Line and to Neutral sustained short circuit test and determination of Zero sequence reactance (Xo). 8. Retardation test for determination of GD2. 9. Three phase sudden short circuit test at 30%En and determination of reactances and time constants.

1.Circuit Dry out Insulation resistance of rotor and stator 2.Resistance of machine winding. 3.Phase sequence test. 4.Hydrogen Leakage tests. 5.Zero Excitation rated speed run 6.Open characteristic curve and losses. 7.Short-circuit characteristic curve and losses. 8.Zero power factor curve point and wattles temperature test. 9.Waveform and harmonic analysis of voltage waveform. 10. Negative sequence and zero sequence reactance. 11. Sudden short circuit and oscillograms. 12. Shipping pressure test.

WORK TEST ON COMPLETED MACHINE PERFORMANCE TESTS: The machine is assembled and erected at the heavy rotating plant test bay for test.

DRY OUT INSULATION RESISTED OF ROTOR AND STATOR WINDINGS: Before starting with running tests, the stator windings are dried out by circulating current in the windings from an external dc source. Input of power is so controlled as to limit the temperature of the end windings to a maximum of 80cby thermometer. Progress of dry out is observed by one minute insulation resistance reading with 1000 volts Mugger. 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 at constant temperature. Ratio of ten minute reading i.e. polarization index, when more than 2 gives an indication of good dry out. Insulation resistance reading of each phase, with others grounded is recorded. Similarly insulation resistance readings of rotor winding to ground are taken.

RESISTANCE OF MACHINE WINDINGS: Measurement of cold winding resistance's, both for stator and rotor must be very accurate since it forms the basis of (a) calculating copper under cold and hot conditions, and (b) for determining the rise in temperature of rotor winding by resistance method at the end of the temperature test. All precautions are taken to as certain while the correct temperature cold resistance of of the turbo winding Since measuring resistance.

winding

generator is quite low; a modified form of whetstone bridge i.e. Kelvins double bridge is employed for measurement .the double bridge is employed for measurement. The 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.

For calculating resistance at any other temperature t2 the following formula is used: FORMULA WRITE K= constant for copper=234.5

PHASE SEQUENCE TEST: The phase sequence test is to check the agreement of the terminal markings that have been specified. Phase sequence indicator. HYDROGEN LEAKAGE TEST: Before admitting hydrogen into the casing, it must be made sure that machine is gas tight and

explosion proof. Its subjected to a pneumatic test or 3.16 kg/cm2.larger leaks are detected by using soap water solution and soon as these are remedied, air supply is cut off to old the pressure in the casing over 24 hours. From initial and final pressure as well as temperature reading, the amount of leakage can be calculated.

ZERO EXITATION RATED SPEED RUN: A trial run is made on the turbo generator to check state of balance and to ensure that the bearings are run in and that bearing oil temperature is reasofromthe nably constant. A synchronous driving motor through speed increasing gears drives the machine. The calibration curve of driving motor with gear is established prior to stator of tests. The machine is brought to rated speed of 3000rpm with no excitation and input readings on the

driving motor recorded by wattmeter method when condition s steady. From the result of above test after deducting derived motor and gear losses, friction and windage 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 bearing loss. From a previous data on seal face losses determined from a prototype test, the total friction loss in bearing and seals can be established. The windage 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 windage. LET US DISCUS BRIEFLY ABOUT ALL THESE TESTS, 1.: EXAMINATION OF THE ROTOR FORGINGS

The rotor, being the most highly stressed part of the turbo generator, must be proved thoroughly sound before it is passed into service. It is subjected to a large number of rigorous dynamic physical, optical and electrical inspection tests. These tests are designed to detect likely flaws in the material, as early as possible. Initial tests are done at forging manufactures works. Specimen pieces are out from the shaft and rotor body and subjected to (a) tensile (b) bending (c) permeability tests to check its conformity with the specification. Sculpture prints are taken at shaft end and on rotor body for microscopic examination to study the presence of supplied. A surface inspection is made after rough machining at steel makers works. Magnetic tests are conducted to disclose detectable any hair cracks process not visually of .The consists

magnetizing the forging and exposing the surface under examination to a stream of paraffin carrying magnetically prepared finely divided iron powder. Fine cracks are disclosed by a concentration of iron particles bridging the cracks under the influence of the magnetic field. The rotor forging is bored along its exits and magnetic crack detection test carried out .the core of a rotor forging is trepanned and rough machined stage these tests detect sub surface unsoundness, cracks or non metallic inclusions. The services of specialist staff in metals section of Research and development division of H.E .are utilized for all the abovementioned tests. ROTOR COIL BINDING RING TESTS:

These are the most highly stressed parts of the rotor, made of non magnetic austenitic steel forging and warm worked by a special process called mandrel Expanding. To avoid local concentration of high stresses, ventilating or locating purposes. Specimen taken from ends of forging are subjected to tensile and bending tests. Crack detection: Magnetic magnetic materials of crack detection .the method

technique is not effective because of the nonrings adopted is dye-penetrating tests. The surfaces to be examined are machined to a smooth finish and are sprayed with a fine white powder, such as French chalk. The dye will appear on the chalk as clearly visible red lines against the white background if cracks are present.

HYDRAULIC TESTS: Rings are subjected to hydraulic tests with oil under pressure, which induces stresses up to 65% of the yield point. Hydraulic test on stator casing: sound top the extent pressure associated of with the purpose

of this tests is to ensure that the frame is withstanding the explosion of a

mixture of air in hydrogenated also to check that all the welds are sound and free from leakage cracks .the test pressure of water for all hydrogen cooled stators is 70 l bs /inch2 irrespective pressure. of casing hour, hydrogen for six design the Every hours,

pressure is first increased to maximum value and then reduced to zero suddenly, thereby giving pressure impacts. Stator core Flux Test: Immediately after the core is built up and before it is wound, a test is made to detect the presence of local

hot

spot.

Whenever

there

are

shorts

between adjacent core lamination s, due to break of inter laminar insulation or burrs on the edges, high eddy currents flow giving rise to temperature rise in that zone. Several turns of cable are wound through the machine bore and out side frame. The winding is fed from a single-phase full working by variable flux voltage 50 to cycles rated core supply. The object is to set up in the core, the corresponding and voltage of the machine. Bad local heating is caused shorted burred laminations and may be detected after a short time by running the hand over the surface of the core. A is set of reading taken as on well core as thermocouples also

external contact thermometers are used to take temperature at other points of yoke and core. The remedy for such defects are to introduce further insulation between laminations and in all, but the worst cases;

this may be done with out dismantling the core. Wattmeter the connected loss and to the by input indicates iron keeping

comprehensive records for every size and type of machine, the readings obtained may be used to estimate the stator core loss in service. By intelligent analysis of the results a bad core with perhaps an excessive iron loss may be detected and remedied before it is wound. ROTOR WINDING AND CELL TESTS BEFORE ASSEMBLY: The rotor coils and their insulation are subjected to high stress when in normal operation. Thus a through 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 wedges, which is cumbersome job. The rotor winding is subjected to a final shipping pressure test

of 3.5 kV for one minute in case of 30 MW and 120MW. TESTS ON ROTOR SLOT CELLS: The epoxy impregnated glass cell forms ground insulation and for H.E.rotors, a voltage test of 10 KV for one minute is applied in the initial stage. Subsequent to the testing of the cell during various stages of assemble at reduced, the entire winding is finally subjected to a shipping test voltage of 3500 volts. TESTS ON ROTOR COILS: TESTS ON ROTOR COILS: Test Between turns: The rotor coil sections are made up of a number of turns which are formed in halves and then assembled with their inter turn insulation and bonded with an adhesive in the steam heated press. Although normal working voltage per turn may be very

small, a turn-to-turn test of 240volts is done to exercise quality control. TOP TURN TROUGH: The insulation at 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 is applied for one minute to test the top through. Test On Complete Rotor Winding: After placing the coil in the slots, before joining after jointing, fitting dampers and wedges and fitting coil binding rings connected to the collector rings up to run at speed, the graded high voltage tests are carried out at each stage, starting with down to shipping pressure test after over speed run. rotor is both in condition. Shipping test on and running standstill

COLLECTOR

LEADS:

high

voltage

equivalent to the shipping test plus 1500 volts is applied to collector leads when fitted in bore with studs of seals fitted but before connecting to windings. TESTS ON STATOR the stator COILS: winding As has per to the be

standards,

subjected to shipping pressure test of (2 line volts +1KV). In case of 30Mwand 120MW generator. In order that machine when wound withstands this final voltage test, and any faulty coil is eliminated during the various stages of coil manufacture and winding. Because the continued application of high voltage tests may over stress the winding insulation, the voltage is reduced at various stages. Test between parallel straps: This is a test of strap insulation provided for eddy E. M. F., a

low voltage of the order of 350 volts for 3seconds is applied. COILS voltage IN of MANUFACTURE 8 K V in AND of WINDING shipping

SECTIONS: When the coils are first tested, a excess pressure test is applied and this voltage tests are repeated. TESTS ON THERMOCOUPLES: 1000 Volts

megger test is applied to the thermocouples.

BALANCING ROTORS: BALANCING:

AND

OVERSPEEDING

OF

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 curves is taken sure those critical speeds of vibration amplitudes. running speed. OVERSPEEDING: In order to check the The design makes sure that the critical speed is well away from the

soundness of all parts and fitting on rotor assembly, the rotor is run at an over speeding test house at Bhopal is one of the most modern in the world. I. OCC: 80 100 110 120

% En Calculated If(A)

Evaluated If(A) If(A) at 100% In on 3 S.C test = Full load If(A) at rated p.f. = S.C ratio = Resistance at 20C (ohm)= Stator Winding Rotor Winding Calculated Evaluated Losses in KW SC St. Cu Losses Calculate d Evaluate d

Rotor Iron Mech. Cu.Losse Losse Losse s s s

2. Determination of SCR %Xd and No load Vn = Ifo = Ife = SCR= Rated output excitation at 0.8 pf Ifn = Xd = Xd = 3. Heat run test

Mech heat run Stator voltage Stator current Rotor field volts Rt field current 4. Cooling medium : Hydrogen Total windage Mechanic and frictional al heat losses run SC losses Iron losses at 110% En Iron losses at 110% In Rotor losses

O.C Heat S.C run at 110% run En

Heat

stator pressurised at 3bar O.C heat run at 110% En S.C heat run

5. Measurement of leakage reactances Zn =Vn / (1.732 X In ) Z =V /(1.732 X I) R =P/(3 X I2 )

Xa =(Z2 X R2 )(1/2) %Xa =(Xa /Zn )X100 %Xp =0.63(%Xa)

6. Capacitance & tan measurement on stator winding Arrangement Volt. R4 N R S C C % appl 3 4 x tan d

7.

Capacitance & tan measurement :

Cx =

C4 X R4 (R3+100) N X (R3 + S)

% tan = ( x R4x C4 x 10-4) x 100 8. Measurement of D.C.resistance of Stator & Rotor Windings : Phase A - A0 B - B0 C - C0 Resistance (mohm) R at 20 C

Winding Stator

9.

Insulation resistance measurement & high voltage test : Phas Phase Before After 15 60 e Earthed High Volt. High

Volt.

Here we use a megger which produce 5000 V 10. Measurement of Ohmic resistance and I.R. values of RTDs. RTD No. Ohmic resistance Insulation Resistance (Mohm)

11. High Voltage test on Rotor Winding : Here we use 1000 V Megger. Rotor Shaft Before After 15 Winding High High Volt. Volt.

60

12. Impedance of Rotor Winding at Stand still and at different speeds. Speed (rpm) V I Z 3000 2000 1000

Stand still Similarly we perform for different frequencies of ac voltage (50-500)Hz. 13. Short circuit heat run test at 100% In : Time Rotor Rotor Curr. Rotor R Volt.

14. Open Circuit characteristic & measurement of losses: Vuv Vvw Vwu %Vn Iv Vd Id Losse s

The same experiment is carried out both in Air and Hydrogen medium. 15. Three phase short circuit characteristic and measurement of losses. Ia Ib %In Ir Vd Id Losse s

PREPARATION FOR STARTING: It is prerequisite for start up of the turbo generator that continuous contacts be maintained between all plant sections directly or indirectly involved in the starting procedure. Checking the Transmitters: Prior to startup, all connections should be rechecked. This applies to piping as well as to cabling. When checking the cabling, special attention should be paid to testing the metering and signal cables. All alarm systems should be checked by changing the setting of the contacts. All temperature measuring points should also be checked. Unless temperature rises were brought about by other preparatory work at the measuring points. When doubt exists regarding the electrical temperature measurements, calibration and line compensation should be repeated. Cooling Water Supply: The coolers should be filled with water on their cooling watersides. To do this, the cooler vents should be opened. RUN UP OF GENERATOR:

Start up of generator: Prior to running the generator oil system should be placed into operation. The oil flow to the bearings should be checked to ensure an adequate flow. In addition, drains should be inspected for proper operation.

Run up: During run up to rated speed, the bearing oil inlet temperature should be in accordance with the turbine manual. During run up the critical speed ranges should be passed through quickly and at a uniform rate. Smooth running depends on several factors. Even minor temperature difference of 1 to 2 dig C between opposite sides of the rotor may result in rotor distortion, which could lead to inadmissible vibrations due to unbalance. Varsity: To protect the rectifier bridge against over voltages occurring during starting or during fault conditions, a non-linear resistor is provided. This protective resistor consists of 6 varistor discs parallel connected between the positive and negative bus rings. The varistor discs are clamped between the bush rings by means of insulated screws. Electrical contact

between the varistor discs and the bus rings is ensured by discs of annealed copper inserted between them. End shields: The end of the brushless exciter are closed by endshields. Depending on the degree of protection of the machine, these endshields have either ventilating slots or welded-on connection pieces for ventilating ducts. The endshields on one end is of split construction and has a split sealing ring screwed to its inner diameter and embracing the sleeve of the rotor hub with little clearance. The end shield on the other end of the exciter is unplugging. Ventilation: The outlet brushless on other with exciter end. used The closed rotor circuit is the cooling, the air inlet being on one end and the spider provided openings, permitting

passage of cooling air past the rectifier heat

sinks and also over the bus rings together with the varistors and the carrier storage-effect circuit. Maintenance: The brushless exciter requires only a minimum of maintenance. The machine is inspected for dust deposits at suitable intervals and are removed when necessary, usually it is found in the region of heat sinks. A suitable method of blowing with compressed air is used for this purpose. MEASURING DEVICES AND SUPERVISORY

EQUIPMENT INTRODUCTION: The supervisory equipment, consisting of alarm and measuring devices gives a visual indication of the system parameters. The supervisory equipments are regulating systems, automatic control and protective devices, which provides for a reduction of the manual supervisory work.

TEMPERATURE DETECTORS Resistance Temperature Detectors (RTDs): Temperature measurements on the generator are made with RTDs. When making measurements with RTDs the resistance element is exposed to the temperature to be measured. The RTD works on principle of the change in electrical resistance of a conductor due to temperature. R = Ro(1 + a.T) Ro= reference resistance at 0C a = temperature coefficient T = temperature in C The temperature coefficient (a) is 3850/deg C, this being the mean value for the range 0 - 100C. Rod Type Thermostats :

Rod-type detecting

thermostats temperature

are limits.

used

for

These

instruments utilize the different coefficients of thermal expansion of two dissimilar metals. When exposed to a temperature rise a rod arranged inside a tube and fitted to one end of it features a linear expansion different from that of the surrounding tube. As a result of this a movement is initiated in a switching head at the other end of the detector tube, which in turn actuates a change over contact. This changeover contact operates on rising and falling temperature when the set value is reached. The contacts are connected to the detector tube. The rod type thermostats are employed for temperature detection in pressurized surroundings. VIBRATION PICKUP Bearing Housing Vibration Measurement:

The vibration pickup for measurement of the absolute bearing vibration converts mechanical vibrations into an electrical signal in a seismic type transducer operating on the permanent magnet plunger coil principle. The permanent magnet and magnetic flux return path elements are solidly connected to the sensor casing. The plunger coil is suspended in the sensor casing by means of a spring. The maximum velocity of the absolute vibration is measured by means of the transducer, which is attached to the bearing housing. Vibration in the bearing housing produce a relative movement between the permanent magnet and the plunger coil, which induces a voltage in the coil portion to the vibration velocity. The output signal of the transducers is integrated amplified and then displayed and recorded as peak-topeak maximum velocity vibration values.