Losses in percentage

60 MW Generator losses

Windage
10%
Rotor Loss
40%
26% Stator Cu. Loss

Stator Fe. Loss

12% 12% Stray losses

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 Losses in 60 MW Air Cooled Generator in Kw.
[Need for cooling]

Windage

132
Rotor
Loss
528
Stator
344 Cu. Loss

Stator
Fe. Loss

Stray
158 losses
158

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 LossesHeatdissipationCooling
• All losses appear as HEAT which must be
removed to keep the temperature within
limits.
• OPTIONS-
• Air cooling.Air filters and fans.It may be like a
TEFC motor.
• Coolers may be inside the casing.

• Hydrogen cooling of Rotor & Stator & Core.

• Hydrogen cooling of Rotor & Water cooling of

Stator.
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 Cooling of Air/Hydrogen in the Generator.
• The HOT air/Hydrogen is cooled by coolers
installed inside the Generator casing.
• These coolers may use C.W. water or
General Service water.
• D.M. water is also used.
• The D.M. water is then cooled in a DM/GS
cooler.
• Coolers may be conventional tubular or
Plate type.

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 Superiority of Hydrogen as a coolant.
Hydrgen
Air Pressure in psi
0.5 30 45
Density 1 0.07 0.14 0.22
Thermal conductivity 1 6.7 6.7 6.7
Heat Transfer Co-efficient 1 1.55 2.7 3.6

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 Where are the losses and heat ? ? ?

• Rotor slots - - - - - - Cu loss

• Stator slots - - - - - Cu loss
• Stator core - - - - - - Iron loss
• Special construction features to carry away the
heat.
• Ventilation ducts in stator core.
• Ducts in rotor slots.
• Fans on rotor for circulation of gases.
• Hollow conductors for stator water cooling.

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 Hydrogen cooling equipments

• Hydrogen and Carbon-di-oxide cylinders.

• H2 and CO2 manifolds and piping, valves
for filling & purging out CO2.
• H2 gas drier.
• [silica gel crystals/Vacuum type]
• Purity meter for continuous monitoring of
gas purity.
• Shaft seal arrangement.

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 Types of conductors
• Older and medium sized Generators were
built with solid conductors for Stator
and Rotor.
• Heat dissipation needed was not much.
• Heat is removed through the insulation.
• That means “Indirect Cooling”
• For higher capacities “Direct cooling” is
needed and so Hollow Conductors
were developed.

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 Rotor Conductors -Types
SOLID HOLLOW

CONDUCTORS CONDUCTORS

Sub-Slot

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 Stator conductors for water cooling.

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 Hydrogen Cooling—Indirect & Direct
100 100

90 90

80 Conductor Temp. 80 Conductor Temp.

70 70

60 60

50 50

40 Hydrogen 40

30 Temp. 30

20 20

10 10

0 0

0 25 50 75 0 25 50

Hydrogen Pressure PSIG-------->>>>>> Hydrogen Pressure PSIG-------->>>>>>

INDIRECT HYDROGEN COOLING DIRECT HYDROGEN COOLING.

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 Hydrogen-CO2 System
Diagram

Generator

Oil
Heater Pressure Regulators
Vent valve

Carbon-di-oxide
AIR
Hydrogen [150Kg/cm.sq].
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 Pre-requisites for CO2- H2 filling.

• Gas tightness test of Generator casing.

• Tube leakage test of H2 coolers in casing.
• Tightness of Stator water cooling system.
• Readyness of Seal oil and Lube oil ckt.
• Both A.C. and D.C. seal oil pumps ready.
• Establish Lube oil and Seal oil circuits.
• Before switching in Seal oil, try to keep casing
pressure of at least 0.5Kg/sq.cm.
• Observe functioning of DPR.

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 CO2 filling process

• Initially Generator casing will contain air.

• Start to admit CO2 through the heater and open the vent
valve to purge out air-CO2 mixture.
• Air will be slowly vented out.
• Keep watch on seal oil pressures.Oil may enter the
Generator.
• Monitor the CO2 content of vented gas till CO2 is above
98% in the vented gas.
• CO2 filling is completed.Keep casing pr.0.50kg/sq.cm
• Close CO2 filling valves.Stop heater also.

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 Hydrogen filling process
• Start H2 filling and venting out the mixture
of CO2 and H2..
• Use H2 cylinders one by one.
• For each cylinder, test the H2 purity before
admitting to the casing.
• Continue filling H2 till purity of vented
gas shows more than 99% Hydrogen.
• Purity can be further raised to 99.7% in
operation.

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 Removal [purging] of Hydrogen.
• Air can not be admitted directly.
• So, start filling CO2 and vent out H2.
• When CO2 in vented gas is above 98%,stop
purging.
• Now admit air in the similar way till CO2 is
purged out.
• Very cold CO2 should not be admitted to
the casing.
• It chills the Generator and moisture
condenses in it.
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 Precautions while filling Hydrogen.
• CO2 should not be kept in Generator for long
periods.
• It is corrosive.
• During this process casing pressure may vary
between 0.5kg/sq.cm to 1.0kg/sq.cm.
• Seal oil pressure will be accordingly low.
• If DPR malfunctions,Gas will leak out or Oil may
enter the casing.
• Close watch is necessary.

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 Ventilation
in VPI
Generator.

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 Ventilation Scheme of Generator

TYPE OF COLING
• OPEN
•COOLING
WATER
MODULE

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 Cross section of Generator.

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 Four Flute cooling system for Rotor

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 Stator Slot Insulation

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 Cross section of Generator

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 Sealing of Generator.

• When Hydrogen cooling is used,

• Sealing system becomes necessary.
• Oil sealing is employed successfully.
• Axial seals
• Radial seals.
• Seal oil circuit.

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 Seal Oil System
Seal Oil System
From Lube
Oil
Generator

D.P.R.

#####
Strainer
VP
Hydrogen
Seperator
Tank
my documents TPS Overview 43

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 Duplex Strainer

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 Inner View-Duplex Strainer

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 RING TYPE H2 SEAL

Bronz Ring

SPRING

AIR HYDROGEN
OIL VIPERS

SEAL OIL SUPPLY

SEAL OIL DRAIN

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 AXIAL H2 SEAL

THRUST

BEARING HYDROGEN
AIR SIDE
SIDE
SEAL

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 Seal oil circuit
• The seal oil tank top is connected to the
Generator casing.
• Seal oil pumps take suction from the bottom
of the tank.
• Oil passes through filters and coolers.
• Then through the DPR.
• Oil pressure is maintained above the
Hydrogen pressure at all times.
• Seal oil is then admitted to the seals.

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• From the seal, the oil has two paths.
• Hydrogen side oil flow. And,
• Air side oil flow.
• Air side oil flow mixes with lube oil flow in
the journal bearing.
• Hydrogen side oil flow goes to seal oil tank.
• From the tank the Seal oil pump again sends
the oil to the seals.
• {through coolers and filters}

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 Seal oil system equipments
• Seal oil tank.
• AC & DC seal oil pumps.
• Duplex Strainers.
• Oil coolers.
• Seal oil tank float valve for level control.
• Differential Pressure Regulator-[DPR].
• Liquid level detectors.
• Pressure and Temperature gages.

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 Case studies
• Koradi 120 MW unit 3.
• Axial seals. Problem of high seal face
temperature.
• Frequently,the Thrust pressure was made
zero
• During purging out H2, casing pressure was
made too low.
• Seal oil entered the casing.
• 21 barrels of oil drained from casing.
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 Khaperkheda 210 MW unit#3
• Unit was at full load.
• Earlier there was a problem with strainer
isolating valves.
• These were 3-way valves & gate valves.
• Supplier representative was checking the
system.
• While operating the valves seal oil supply
was cut off.
• H2 escaped from in-board seal &caught
fire.
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 Steps to avoid accidents.
• Study the system well.
• Note awkward location of valves and
equipments.
• Take possible corrective steps in advance.
• Ensure that all operators are fully familiar
with the system.
• The last is most important as ignorance may
result in serious accidents.

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 3-Way valve operation
ROTATE UPPER VALVE QNTICLCKWISE
LOWER VALVE CLOCKWISE.
FOR UPPER VALVE ONLY

B IN SERVICE

BOTH CUT OFF

A B

A IN SERVICE

BOTH IN SERVICE
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 Transposition of
Stator Bars

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Rotor without end-bells

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 Rotor with retaining rings
[end – bells ]

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 Bar Insulation

INSLATED. HIGH VOLTAGE

COPPER INSULATION
STRIPS

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 Rotor Slots

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 Assembled Core

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 Retaining Rings {End-bells}

•NON-MAGNETIC, COLD WORKED MATERIAL

• WITHSTANDS CENTRIFUGAL FORCES DUE TO THE END
WINDINGS
• SHRUNK FIT HUB REINFORCES RETAINING RING AND
SECURES THE END WINDING IN THE AXIAL DIRECTION
• SNAP RING PROTECTS AGAINST AXIAL DISPLACEMENT OF
THE RETAINING RING.
• SHRINK SEAT AREA IS SILVER PLATED

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 Stator Core Building

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 Core Assembly

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 Stator Coils Formation

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 Lower Half Bearing

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 Complete Bearing

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 Salient Design Features of Bars.

 Roebel bars with 3600 transposition to

reduce eddy current losses
 Double glass lapped copper conductors.
 Multi turn design for low capacity high
voltage machines
 Resin rich mica / resin poor VPI insulation.
 Corona protection of straight part insulation.

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