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
AIR COOLED

HYDROGEN COOLED

HYDROGEN/WATER
COOLED

GENERATOR MODULE

OUTPUT RANGE

TARI 93/38
TARI 108/36
TARI 108/41
TARI 108/46

75-92 MW
100-120 MW
120-140 MW
140-170 MW

THRI 93/38
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

120-150 MW
200-260 MW
260-275 MW
350 MW
UPTO 200 MW
200-219 MW
220-237 MW
500-585 MW
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
Cover

End Shield
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 machines 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
SLOT PART
Both closely compensate
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 semiconducting 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

15.75 kV

MAN

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
DIODES

FIELD
(PM)
PILOT
EXCITER

MAIN
EXCITE
R

GENERATOR

BRUSHLESS EXCITATION - BASIC

EXCITATION SYSTEM SCHEME
BRUSH FOR E/F DETECTION
PILOT EXCITER
QUADRAT. AXIS
COIL
EXCITER

AVR

R - C BLOCK
+

TG ROTOR
TG STATOR

PMG Rotor & Fan

Rectifier Wheel

Comparison
S.NO

Description

Brushless Excitation

Static Excitation

Type of system.

Brushless system gets activated

with pilot exciter, main exciter
and rotating diodes.

Dependency on external
supply.

No external source requirement

since pilot exciter has
permanent magnet field.

Response of the excitation

system.

Requirement of additional
bearing and increase
of turbo generator
shaft length.

One additional bearing and an

increase in the shaft length
are required.

No additional bearing and increase

in shaft length are required.

Maintenance.

Less since sliprings and brushes

are avoided.

More since slip rings and brushes

are required. Also over hang
vibrations are very high
resulting in faster wear and
tear.

Slower than static type since

control is indirect (on the field
of main exciter) and
magnetic components
involved.

Static excitation system uses

thyristors & taking supply from
output of the generator
Field flashing supply required for
excitation build up.

Very fast response in the order of

40 ms. due to the direct control
and solid state devices
employed.

Auxiliary System
1.Gas Flow System
2. Seal Oil System
3. Primary Water System

HYDROGEN GAS SYSTEM

H2 DISTRIBUTOR
+

CO2
GAS ANALYZER

H2 DRIER
OUT

HYDROGEN

AIR

CO2

WASTE
DETECTOR

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
WASTE GAS

PW TANK
PUMPS

}{

F
F

FLOW }{
METERS

NaOH

M
M

}{

}{

F
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
1.0

PERMISSIBL
E
ZONE

0.1
0.05 HCl
0.01
6

10

NaOH
7

pH AT 18 C

HOLLOW COPPER CORROSION - 3

10 000 HRS. SIMULTAED TESTS

COROSION
RATE P.U.
7 PERMISSIBLE

ZONE

pH = 7

pH= 8

10

100

pH= 8.5
250 1000 5000

O2 CONCENTRATION ppb

Seal Oil System

Prevents H2 losses at the shaft entry into stator

H2 SIDE SEAL OIL

BRG.5

BRG.-6

H2

PRE-CHAMBER

L.O.

L.O.

SYPHON
BVEF

AIR SIDE SEAL OIL

GENERATOR

HIGH LEVEL

MOT

H2

DC

Thank You