MANUFACTURING AND ASSEMBLING OF STATOR AND ROTOR INTURBO GENERATORS

STATOR FRAME The stator frame is of welded steel single piece construction. It supports the laminated core andwinding. It has radial and axial ribs having adequate strength and rigidity to minimize corevibrations and suitably designed to ensure efficient cooling. Guide bars are welded or boltedinside the stator frame over which the core is assembled. Footings are provided to support thestator foundation. STATOR CORE The stator core is stacked from the insulated electrical sheet steel lamination andmounted in supporting rings over the insulated dovetail guide bars. In order to minimize eddycurrent losses core is made of thin laminations. Each lamination layer is made of individualsections. The ventilation ducts are imposed so as to distribute the gas accurately over the coreand in particularly to give adequate support to the teeth.The main features of core are 1. To provide mechanical support.2. To carry efficiently electric, magnetic flux.3. To ensure the perfect link between the core and rotor. THE PURPOSE OF STATOR CORE To support the stator winding To carry the electromagnetic flux generated by rotor winding.So selection of material for building up of core plays a vital role. The losses in the core are of two types. Hysterysis Loss Due to the residual magnetism in the core material.Hysterysis loss is given byWh max 1.6 Eddy Current Loss: Due to the e.m.f induced in the core of the stator. Eddy current loss isgiven byWe max2 f2 t2In order to reduce the hysterysis loss, silicon alloyed steel, which has low hysterysis constant isused for manufacture of core. The composition of silicon steel isSteel - 95.8%Silicon 4.0%Impurities 0.2%From the formula it is seen that eddy current loss depends on the thickness of the laminations.Hence to reduce the eddy current loss core is made up of thin laminations which are insulatedfrom each other. The thickness of the laminations is about 0.5mm. The silicon steel sheets are of COLD ROLLED NON-GRAIN ORIENTED (CRANGO) type as it provides the distribution of flux throughout the laminated sheet. PREPARATION OF LAMINATIONS For high rating machines each laminations is build of 6 sectors (stampings), each of 60 cutaccording to the specifications. Press tools are used in the manufacture of laminations. Presstools are mainly of two types. Compounding tools. Blanking and slot notching tools. COMPOUNDING OPERATION In this method the stamping with all the core bolt holes, guiding slots and winding slots ismanufactured in single operation known as Compounding operation and the press tool used isknown as Compounding tool. Compounding tools are used for the machines rated above 40 MW.

BLANKING AND NOTCHING OPERATIONS In case of smaller machines the stampings are manufactured in two operations. In the firstoperation the core blot holes and guiding slots are only made. This operation is known asBlanking and the tools used are known as Blanking tools. In the second operation the windingslots are punched using another tool known as Notching tool and the operation is called Notching Deburring operation In this operation the burrs in the sheet due to punching are deburred. There are chances of short circuit within the laminations if the burrs are not removed. The permissible is about 5micrometer. For deburring punched sheets are passed under rollers to remove the sharp burs of edges. Varnishing Then depending on the temperature withstand ability of the machine the laminations arecoated by varnish which acts as insulation. The lamination sheets are passed through conveyor,which has an arrangement to sprinkle the varnish is obtained. The sheets are dried by a series of heaters at a temperature of around 260-350 C. Two coatings of varnish are provided in the abovemanner till 1218mm thickness of coat is obtained. ASSEMBLY OF CORE The stator laminations are assembled as separate cage without stator frame. The entire corelength is made in the form of packets separated by radial ducts to provide ventilating passagesfor the uniform cooling of the core. The thickness of each lamination is 0.5mm and the thicknessof lamination separating the packets is about 1mm. The lamination separating each packet hasstrips of nonmagnetic material that are welded to provide radial ducts.

ROTOR: Rotor is the rotating part of alternator. It is used to support field winding placed in slots on therotor. FOR 2-POLE GENERATOR Solid rotors are manufactured from forged alloy steel with suitable alloying elements to achievevery high mechanical and superior magnetic properties. This type of rotor can withstand evenupto speed of 3000 rpm. Rectangular or trapezoidal rotor slots are accurately machined to closetolerances on slot milling machine.For indirectly cooled generator rotors, ventilation slots aremachined in the teeth. FOR 4-POLE GENERATOR For directly cooled rotors, sub slots are provided for cooling Generator rotors of 1500 RPM areof round laminated construction. In this case rotor is made up of two parts (1) core, (2)lamination. The outer diameter of core and the inner diameter of laminations are equal. So for inserting the core inside the laminations the laminations are first red heated at mediumtemperature for 15 hours in BELL FURNACE. After that the core is shrunk fitted inside thelaminations. Thus punched and varnished laminations of high tensile steel are mounted over machined shaft and are firmly clamped by end clamping plates.

ROTOR SHAFT Rotor shaft is a single piece solid forming manufactured from a vacuum casting. It is forged froma vacuum cast steel ingot. Slots for insertion or the field winding are milled into rotor body. Thelongitudinal slots are distributed over the circumference such that two solid poles are obtained.To ensure that only a high quality product is obtained, strength tests, material analysis andultrasonic tests are performed during the manufacture of rotor. The high mechanical stressesresulting from the centrifugal forces and short circuit torques call for a high quality heat treatedsteel. After completion, the rotor is balanced in various planes at different speeds and thensubjected to an over speed test at 120% of the rated speed for two minutes ROTOR WINDINGS The rotor windings consist of several coils inserted into the slotsand series connected such that two coil groups form one pole. Each coil consists of several seriesconnected turns, each of which consists of two half turns connected by brazing in the endsection. Thickness of each strip can be made upto 10.5 mm but here in BHEL we make only upto5.3 mm. The rotor bearing is made of silver bearing copper ensuring an increased thermalstability. For ventilation purpose the slots are provided on the coil and on inter strip insulationlayer both.The individual turns of coils are insulated against each other by interlayer insulation. L-shapedstrips of laminated epoxy glass fiber fabric with nomex filter are used for slot insulation. The slot wedges are made of high electrical conductivity material and thus act as damper windings. At their ends the slot wedges are short circuited through the rotor body. The inter space between the overhang is called slot through CONSTRUCTION The field winding consists of several series connected coils inserted into the longitudinal slots of rotor body. The coils are wound so that two poles are obtained. The solid conductors have arectangular cross section and are provided with axial slots for radial discharge or cooling air. Allconductors have identical copper and cooling duct cross section. The individual bars are bent toobtain half turns. After insertion into the rotor slots, these turns are brazed to obtain full turns.The series connected turns of one slot constitute one coil. The individual coils of rotor areconnected in a way that north and south poles are obtained . CONDUCTOR MATERIAL The conductors are made of copper with a silver content of approximately 0.1%. As compared to electrolytic copper, silver alloyed copper features high strength properties at high temperatures so that coil deformations due to thermalstresses are eliminated. INSULATION The insulation between the individual turns is made of layer of glass fiber laminate.The coils are insulated from the rotor body with L-shaped strips of glass fiber laminate withnomex interlines.To obtain the required leakage paths between the coil and the rotor body thick top strips of glassfiber laminate are inserted below top wedges. The top strips are provided with axial slots of thesame cross section and spacing as used on the rotor winding. Insulation b/w overhang is done by blocks made of HGL

ROTOR SLOT WEDGE To protect the winding against the effects of centrifugal forces, the winding is secured in theslots with wedges. The slot wedges are made of copper alloy featuring high strength and goodelectrical conductivity. They are also used as damper winding bars. The slot wedges extend beyond the shrink seats of retaining rings. The wedge and retaining rings act on the damper winding in the event of abnormal operations. The rings act as short circuit rings in the damper windings. END WINDING BRACING The spaces between the individual coils in the end winding are filled with insulated membersthat prevent coil movement. Two insulation plates held by HGL high glass laminate platesseparate the different cooling zones in the overhangs on either sides . ROTOR RETAINING RINGS The centrifugal forces of the rotor end winding are contained by single piece rotor retainingrings. Retaining rings are made of non-magnetic high strength steel in order to reduce straylosses. Each retaining ring with its shrink fitted. Insert ring is shrunk on to the rotor body in anoverhang position. The retaining ring is secured in the axial position by snap rings.Fig: rotor retaining ringsThe rotor retaining rings withstand the centrifugal forces due to end windings. One end of eachring is shrunk fitted on the rotor body while the other end overhangs the end windings withoutcontact on the rotor shaft. This ensures an unobstructed shaft deflection at the end winding. ROTOR FANS The cooling air in generator is circulated by two axial flow fans located on the rotor shaft one ateach end. To augment the cooling of the rotor winding, the pressure established by the fan worksin conjunction with the air expelled from the discharge parts along the rotor. The blades of thefan have threaded roots for being screwed into the rotor shaft. The blades are drop forged froman aluminium alloy. Threaded root fastenings permit angle to be changed. Each blade is securedat its root with a threaded pin.