- Rakesh Kumar

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BHEL Haridwar Electrical Machine Engineering
 Capability of Generator Modules

125/67
115/67

800

108/55
108/44 (VPI)
108/39 108/44
93/38

115/52

250

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BHEL Haridwar Electrical Machine Engineering
 270 MW Turbo Generator

1. Generator Module – THRI 108/44

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BHEL Haridwar Electrical Machine Engineering
 270 MW Turbo Generator
2. Operating Parameters
Parameters 250 MW 270 MW
Rated Voltage 16.5 KV 16.5 KV
Stator Current (Amps) 10291 11115
Rotor Current (Amps) 2497 2666
Rotor Voltage (V) 299 325
SCR 0.63 0.58
Hydrogen Pressure (bar) 4 4
Heat Load (KW) 2650 2900
Stator Wdg Temp (°C) 93 98
Rotor wdg Temp (°C) 81 84.5
Core temp (°C) 65 67
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BHEL Haridwar Electrical Machine Engineering
 Design Constraints & Solution (270 MW)

STATOR
CASING

OPENING
FOR
COOLERS

END SHIELD

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BHEL Haridwar Electrical Machine Engineering
 Design Constraints & Solution (270 MW)

ORIGINAL
CONTOUR

NEW
CONTOUR

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BHEL Haridwar Electrical Machine Engineering
 Design Features (270 MW)

• Stator Winding Bars with 540° Transposition & 2-Plane

Bending:
THRI designs so far manufactured by BHEL are with
360°/single plane transposition. Adoption of 540°
transposition leads to manufacturing simplicity as strip to
strip brazing is eliminated.

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BHEL Haridwar Electrical Machine Engineering
 540° Transposition of wdg conductors (270 MW)

540 Deg Transposition

Strip to strip brazing is eliminated.

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BHEL Haridwar Electrical Machine Engineering
 More Efficient Coolers (270 MW)
Cooler Parameters -
Parameters 250 MW 270 MW
Inlet Water temp (°C) 38 38
Cold gas temp (°C) 45 43
Cooling Water Flow m3/hr 280 350

Special Features –
1. Special fin configuration has been developed.
2. Pitching has been reduced and manufacturing shall be
done in close tolerances.
3. Cold gas temperature achieved shall be below normal
requirement.

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BHEL Haridwar Electrical Machine Engineering
 Design Features (270 MW)

1. 540° transposition of winding conductors

2. Elimination of strip to strip brazing leading to manufacturing
time cycle reduction
3. Strengthening of stator winding overhang
4. Total VPI core and stator windings
5. More efficient twin Hydrogen coolers
6. Increase in transportation weight – 3 Tons (approx)

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BHEL Haridwar Electrical Machine Engineering
 525 MW TURBO GENERATOR

Water Cooled Stator Winding PW Tank Stator Core

Compressor
(on TE only)

Rotor

End Shield Mounted Bearings

Module – THDF 115/59 Terminal Bushings

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BHEL Haridwar Electrical Machine Engineering
 525 MW TURBO GENERATOR
1. Generator Module – THDF 115/59
2. Operating Parameters
Parameters 500 MW 525 MW
Rated Voltage 21 KV 21 KV
Stator Current (Amps) 16291 16981
Rotor Current (Amps) 4040 4213
Rotor Voltage (V) 340 355
SCR 0.52 0. 49
Heat Load (KW, H2 Coolers) 4639 4963
Hydrogen Pressure (gauge) 3.5 4.0
Primary Water Flow(m3/hr) 65 75
Shaft Seal System Double Flow Single Flow
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BHEL Haridwar Electrical Machine Engineering
 600 MW Generator

Module – THDF 115/67

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BHEL Haridwar Electrical Machine Engineering
 Axial Cooling of Stator Core

Better ratio of overall core length to effective core length

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BHEL Haridwar Electrical Machine Engineering
 Axial Cooling of Stator Core

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BHEL Haridwar Electrical Machine Engineering
 Optimisation of Compressor Stages

500 MW - FIVE STAGES 600 MW - THREE STAGES

• Less resistance for Stator Core cooling and optimised rotor,

less pressure across compressor
• Reduced compressor losses and hence higher efficiency

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BHEL Haridwar Electrical Machine Engineering
 Core Insertion into Stator

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BHEL Haridwar Electrical Machine Engineering
 TE End Shield in two parts

Cooler Housing Frame

Easier to handle and

assemble at works/site.

End Shield

Cooler Housing Frame

houses vertical coolers and
End Shield houses bearings ,
shaft seals etc.

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BHEL Haridwar Electrical Machine Engineering
 Rotor Slot & Wedge

SINGLE INDENT
WEDGE -
DOUBLE INDENT SIMPLIFICATION
WEDGE

TRAPEZOIDAL
SLOT SHAPE PARALLEL SLOT -
VARIETY
REDUCTION

600 MW
500 MW

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BHEL Haridwar Electrical Machine Engineering
 Rotor Cooling Duct

500 MW - NINE SHAPES 600 MW - SHAPE SLOT

600 MW - SHAPE
OVERHANG

Increased cooling duct size in 600 MW design

Provides better cooling
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BHEL Haridwar Electrical Machine Engineering
 Rectangular Rotor End Winding

Replaces earlier
Circular coils with
Simple design.
Resulting in time
Cycle reduction.

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BHEL Haridwar Electrical Machine Engineering
 Seal Oil System
• Single flow Ring Type Shaft Seals

• Simple construction and easy O & M

SINGLE FLOW - 600 MW DOUBLE FLOW - 500 MW

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BHEL Haridwar Electrical Machine Engineering
 Technical Parameters

Parameter Unit 600 MW 500 MW

Rated Voltage kV 21 21
Rated Current Amp 19407 16166
Hyd. Press. (g) Bar 5 3.5
P.F. - 0.85 0.85
Transportation mm 9875x3880 8830x4100
LxW
Stator T 316 265
Transportation
Weight

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BHEL Haridwar Electrical Machine Engineering
 Collaborator’s Experience

Paiton Phase II, Unit 5 Indonesia 1999

Paiton Phase II, Unit 6 Indonesia 1999

Hanfeng Unit 1 China 2000

Hanfeng Unit 2 China 2001

Iskenderun Unit 1 Turkey 2003

Iskenderun Unit 2 Turkey 2003

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BHEL Haridwar Electrical Machine Engineering
 THANK YOU

END

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BHEL Haridwar Electrical Machine Engineering