500 MW GENERATOR

Technical Specification
 Make: BHEL
 Type: THDF 115/59
 Cooling stator winding: Directly water cooled
 Cooling stator core and rotor: Directly hydrogen
cooled
 588 MVA, 500 MW, 21 kV, 16200 A, 0.85 pf (lag),
50 Hz, 3000 rpm
 Hydrogen Pressure: 4.0 Kg/cm2
 Short circuit ratio: 0.48
 Class and type of insulation: MICALASTIC (similar
to class F)
 No. of terminals brought out : 6
 Types of Turbo generator

Generator Modules:
Air Cooled Turbo generator
• TARI
Hydrogen Cooled Turbo generator
• THRI
Hydrogen/Water Cooled Turbo generator
• THDF (500 MW) and THW (210 MW)
Generator cooling System
 Capability of Generator Modules
DESIGN VARIANT GENERATOR MODULE OUTPUT RANGE

TARI 93/38 75-92 MW

AIR COOLED TARI 108/36 100-120 MW
TARI 108/41 120-140 MW
TARI 108/46 140-170 MW

THRI 93/38 120-150 MW

HYDROGEN COOLED THRI 108/44 200-260 MW
THRI 108/44 B 260-275 MW
THRI 108/55 350 MW
THW-200-2 UPTO 200 MW
HYDROGEN/WATER THW-210-2 200-219 MW
COOLED THW-235-2 220-237 MW
THDF 115/59 500-585 MW
THDF 115/55 500 MW(new)
 COOLING SYSTEM

STATOR SLOT

ROTOR SLOT

THDF THWW
Rotor Slot Cooling
 THDF: Ventilation Scheme
• Gas flow path 1 enters rotor on Turbine
end and cools rotor overhang and slots
• Gas flow path 2 cools stator core
• Gas flow 3 enters rotor on exciter end &
cools rotor overhang & slots, as well as
stator core end parts at both the ends
• Hot gas from all paths returns through air
gap to compressor, and to coolers
THDF: VENTILATION SCHEME
 Main Components
• Stator
– Stator Frame
– Stator Core
– Stator Winding
– Gas Coolers
– End Shields
• Rotor
– Rotor Shaft
– Rotor Winding
– Rotor Retaining Ring
– Field Lead Connection
– Fan
 Main Components
• Bearing
• Shaft Seals
• Terminal Bushing
• Auxiliary System
– Seal oil system
– Gas system
– Primary water system
– Excitation system
 Main Parts of Turbo generator
Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing
 Stator Body
• Fabricated cylindrical gas tight steel structure with
suitably welded circular ribs internally to provide
rigidity
• Ring shaped support for resilient core suspension
arranged between circular ribs
• Can with stand explosion pressure of hydrogen air
mixture without any residual deformation
• Hydrogen gas coolers housed longitudinally inside
stator body
• End shields which are gas tight and pressure
resistant for closing casing and supporting fans
and shaft seals
• Firmly connected to foundation with anchor bolts
through the feet
Stator Frame (Fabrication & Machining)
Stator Frame TARI 108/46
 Main Parts of Turbo generator

Coolers

Foundation

Terminal bushing
 Stator Core
• It provides path for machine’s magnetic flux and has slots
in which windings are assembled
• Made up of segmental, varnish insulated punching of
steel
• Vent segments at designed intervals for flow of cooling
gas
• Axially compressed with pressure plate, clamping fingers
and non magnetic through type clamping bolts which are
insulated from the core
• Supporting rings form part of inner frame cage which is
suspended in outer frame by large no. of separate flat
springs
• Springs are so arranged and tuned that forced vibration of
core resulting from magnetic field will not be transmitted
to frame and foundation
500MW TG: STATOR CORE

CAGE

FLAT SPRING

CORE BAR
 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, hydrogen
coolers, oil catchers, etc
•Provision for supply of Bearing Oil, Seal oil, Thrust
oil and its drain
End Shield (Exciter side 500 MW)
End Shield (Turbine side 500 MW)
 Stator Winding
• Generator voltage is induced in the stator windings
and each conductor must be capable of carrying
rated current without getting overheated
• Three phase windings is double layer of individual
bars
• Each stator slot accommodates two bars
• Coil groups connected to Connecting Bus bar and
finally to Terminal Bushing
• The lengths of the overhang and the angle of
overhang is optimized so as to give the minimum
length of overhang
 Stator Winding
• The upper layer of the winding bar is laid in the slot
and separated from the lower bar by means of
glass textolite packing
• Both the bars are held in the slot by means of
impact resistant plastic wedges
• The wedging is ensured to be very tight so that
during the operation of the machine the same
should not get loosened
• For protection against effects of magnetic forces
due to load and to ensure permanent firm seating
of bars in slots during operation, side ripple spring,
and top ripple located beneath the slot wedge are
inserted
STATOR SLOT
Ripple spring of generator
 Stator Winding
• Stator bars, phase connectors and bushings are direct
water cooled
• To minimize stray losses, bars are composed of separately
insulated strands Roebel transposed by 540O in slot portion
and bonded together with epoxy resins in heated molds
• Bars consist of hollow and solid strands distributed over
entire bar cross-section for good heat dissipation
• The use of combination of several groups each consisting
of two solid and one hollow conductor effectively reduces
the depth of the slot which affect the losses in the winding,
and better utilization of slots
• At bar ends, all solid strands are jointly brazed into a
connecting sleeve and hollow strands into a water box
• Stainless steel ring headers and black Teflon tubes used for
primary water
• Annular water manifolds insulated from stator frame
• MICALASTIC insulation is used
 STATOR WINDING BARS
• Due to variable magnetic flux distribution
along stator slot height, inductance of strips
in a bar are different
• In a bar with straight strips
therefore,current distribution
shall be non-uniform
• This is compensated by
twisting these strips in a bar in its slot
part, known as transposition. Such bars
are also called Roebel transposed bars
 ROEBEL BARS
• Such transposition of strips equalizes
their inductances, so that there can be no
circulating currents internally amongst them
even if the bar ends at nose joints are
shorted
360°
• Transposition is either
360°- KWU practice or 540°
540° Russian practice
• Both closely compensate SLOT PART
for slot part. However, there are overhang
parts
 Stator Winding
 Adequate protection provided to avoid corona and
surface discharge
 To minimize corona discharges between the
insulation and the slot wall, a final coat of semi-
conducting varnish is applied to the surfaces of all
bars within the slot range
 High-quality mica, selected epoxy resins and a
matching vacuum impregnation process (VPI) are
the characteristic features of the Micalastic
insulation for large turbo generators
 RTDs are Provided to record temp
Stator End Winding Assembly
 Rotor Shaft
• High mechanical stresses resulting from centrifugal
forces and short circuit torques calls for high quality
treated steel
• A high strength low alloy steel single forging
prepared by vacuum cast steel ingot
• Slots for housing field windings longitudinally and
are distributed over the circumference so that two
solid poles are obtained
• Supported on two journal Bearings
• Two axial fans are mounted on both sides of the
rotor
• Special ducts (fins) are provided in the rotor body,
through which the cooling gas flows to the rotor end
windings
 Rotor Shaft
• Due to non uniform slot distribution on
circumference, different moment of inertia
are obtained in the main axis of rotor and
causing oscillating shaft deflection at twice
the system frequency
• Vibrations are compensated by transverse
slotting of pole (cross pole slots)
• After completion, the rotor is balanced in
various planes at different speeds and then
subjected to an over speed test at 120% of
rated speed for two minutes
 Rotor Body with cross Pole Slot

Rotor
Wedge

Cross
Pole
Slot
 Rotor Winding
• Made from hard drawn silver bearing de-oxidized copper
hollow conductors having trapezoidal cross-section with two
lateral cooling ducts
• Inter turn insulation is class ‘F’ laminated glass-epoxy
• Slot insulations are L-shaped cells of glass-Nomex-epoxy
resin
• Rotor windings held in position against centrifugal forces by
wedges in slot portion and by non-magnetic steel retaining
rings in overhang portion
• Slot wedges are made from copper-nickel-silicon alloy and
silver plated featuring high strength and good electrical
conductivity of eddy currents flowing on rotor surface in
case of unbalance or asynchronous machine operation and
used as damper winding bars
Rotor End Winding
 Rotor Retaining Ring
• The non-magnetic (to reduce stray losses) retaining ring
contain the centrifugal forces due to end windings
(overhang part of the winding)
• One end of each ring is shrunk on rotor body, while other
end overhangs the end windings without contacting the
shaft to ensure an unobstructed shaft deflection at the end
windings
• Snap ring is provided for additional protection against axial
displacement of retaining ring
• Class ‘F’ layers electrically insulate the ring from the copper
underneath
• Seating surfaces of rings and the shaft are silver coated
• Retaining ring shrink-fit areas act as short circuit rings to
induce currents in damper system
 Field Connections
• Rotor field current leads are connected to the
brushless exciter leads at the exciter coupling with
silver plated Multikontakt plug-in contacts which
allow for unobstructed thermal expansion of the
field current leads
• Current from field leads is transferred to rotor coils
by means of thread less special current carrying
bolts which are adequately sealed by rubber rings
to avoid any hydrogen escape
• The radial terminal bolts and two semicircular
conductors located in the hollow bores of the
exciter and rotor shafts
 Terminal Bushing
• Water cooled terminal bushings housed
in lower part of stator on exciter end side
• Terminal bushings are housed in a
chamber of non-magnetic steel plates
and effecting sealing provided between
bushings and stator body
• Three phase and three neutral terminals
brought out
 Main Parts of Turbo generator

Coolers

Foundation

Terminal bushing
Terminal Bushing Box 500 MW
 Excitation System
Static Excitation
• Rotor Field Winding is connected to Slipping mounted on
rotor
• Excitation is provided by current transfer by contact through
Carbon Brushes, Slip ring and field lead

Brush Gear
 STATIC EXCITATION SYSTEM ( 210 MW)

575 v

AVR
AUTO

MAN
15.75 kV

FB

FF

FDR

415 v AC
 Static Excitation System

Brush Gear Assly Brush Holder

 Brushless Excitation System
Brushless Exciter

•Eliminates Slip Rings, Brushgear and Field Breaker

•Eliminates all problems associated with transfer of current via

sliding contacts

•Simple, Reliable and ideally suited for large sets

•Minimum operating and maintenance cost

•Self generating excitation unaffected by system fault/disturbances

because of shaft mounted pilot exciter

•Increasingly popular system the world over

 Brushless excitation

FIELD BREAKER R
Y
ARMATURE
ROTATING B
DIODES

FIELD
(PM)

MAIN GENERATOR
PILOT
EXCITER EXCITE
R
 BRUSHLESS EXCITATION - BASIC
EXCITATION SYSTEM SCHEME
BRUSH FOR E/F DETECTION
PILOT EXCITER
AVR QUADRAT. AXIS
COIL
EXCITER

R - C BLOCK

+
TG ROTOR
TG STATOR
PMG Rotor & Fan
Rectifier Wheel
 Comparison
S.NO Description Brushless Excitation Static Excitation
1 Type of system. Brushless system gets activated Static excitation system uses
with pilot exciter, main exciter thyristors & taking supply from
and rotating diodes. output of the generator

2 Dependency on external No external source requirement Field flashing supply required for
supply. since pilot exciter has excitation build up.
permanent magnet field.

3 Response of the excitation Slower than static type since Very fast response in the order of
system. control is indirect (on the field 40 ms. due to the direct control
of main exciter) and and solid state devices
magnetic components employed.
involved.

4 Requirement of additional One additional bearing and an No additional bearing and increase
bearing and increase increase in the shaft length in shaft length are required.
of turbo generator are required.
shaft length.

5 Maintenance. Less since sliprings and brushes More since slip rings and brushes
are avoided. are required. Also over hang
vibrations are very high
resulting in faster wear and
tear.
 Auxiliary System

1.Gas Flow System

2. Seal Oil System

3. Primary Water System

 HYDROGEN GAS SYSTEM
H2 DISTRIBUTOR

+
CO2
H2 DRIER
GAS ANALYZER OUT

HYDROGEN

WASTE
AIR DETECTOR
CO2

 65 bar
 Coolant Temperature Control
• Load changes lead to mechanical
stresses as there is unequal expansion of
winding copper, insulation and core iron due
to their unequal thermal expansion
coefficients
• CW flow to Hydrogen gas coolers is varied
with load automatically, so as to achieve
uniform temperatures at different loads
• Cold gas temperature is changed with load
by sensing stator current
 Primary Water System
Losses in wdg, bushings, bus bar are dissipated
1. PRIMARY WATER TANK
2. PRESSURE REGULATOR
3. WASTE GAS TO ATM.
4. PUMP
5. COOLER
6. FILTER
7. BYPASS LINE
8. CW FOR STATOR WDG.
9. ION EXCHANGER
10. CW FOR BUSHINGS
11. TEFLON HOSE
12. C W MANIFOLD
13. ALKALISER UNIT
 STATOR WINDING PRIMARY WATER
N2 GAS
PW TANK
WASTE GAS
PUMPS

}{
F

NaOH M
F

M
FLOW }{ }{ }{
METERS F M
F
 Primary Water Treatment System
• PW pumps have effective gland sealing to
prevent air suction (if air is sucked, O 2
increase and conductivity value shall go up
and also Cu corrosion rate goes up)
• Mixed bed ion exchanger removes Cl- and
HCO3 ions to prevent loss of alkalinity
(keep conductivity low)
• Na+ are also removed, but later added by
dilute NaOH injection
• 5 micron filter to arrests resin particles
• Integrating flow meter and conductivity
meter provided
 HOLLOW COPPER CORROSION
• Low / high O2 give low corrosion
• Low O2 level below 100ppb, say 10 - 20 ppb
recommended for 500 MW TG
• Conductivity:<10 micro mho/cm, say: 0.5
• CO2, Chlorides and other anions to be minimum
• Conductivity after strongly acidic cation exchanger <
0.2 micro mho/cm
• NH3 to be minimum
• Cu & Fe dissolved / un dissolved < 20ppb
• pH of 8.5 to 9 gives optimum results
• Dilute 1 - 2% NaOH is added to obtain pH levels
and Integrated alkalyzer unit is used (Conductivity
increases)
 Conductivity vs pH
MICRO
MHOS/CM
10 10
PERMISSIBL
E
1.0 ZONE

0.1
0.05 HCl NaOH

0.01 pH AT 18° C
6 7 8 9
 HOLLOW COPPER CORROSION - 3
10 000 HRS. SIMULTAED TESTS
COROSION
RATE P.U.
7 PERMISSIBLE
ZONE
5
pH = 7
3

1 pH= 8 pH= 8.5

10 100 250 1000 5000
O2 CONCENTRATION ppb
 Seal Oil System
Prevents H2 losses at the shaft entry into stator
 AIR SIDE SEAL OIL
GENERATOR
BRG.5 H2 BRG.-6
H2 SIDE SEAL OIL

PRE-CHAMBER
L.O. L.O.
SYPHON

BVEF
HIGH LEVEL

MOT
1 2 DC
H2
Thank You