Synchronous Hydro Generator

Presented by
Motilal Senapati
Asst. Director
NPTI(ER), Durgapur
 Contents
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I – Function & Working Principle

II – Classification
III – Different Types
IV – Main Components
V – Auxiliaries
VI – Erection Sequence
VII – Excitation System
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I – Function & Working Principle

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BASIC PRINCIPLE
• Generator is the device that converts mechanical energy into electrical energy

Basic Principles - Synchronous Machine

Stator (3-phases, AC Power)

Pv1 Pv2 Pv4 Pv3

Rotating
field type
TURBINE
synchronous
n
Rotor machine
BEARING
COUPLING

Pmec Excitation (DC)

120 x Frequency f f : given by the grid [Hz]

No. of poles, p =
Synchronous speed n n : given by the turbine [rpm]
II – Classification
 Generator classification
Generator

AC DC

Synchronous Induction

Mounting Size Construction Prime mover

Horizontal Small Salient Hydro

Vertical Medium Cylindrical Turbo

Large Diesel Engine

 Hydro Turbines
Types:-
 Pelton :-
 Used for head H = 300 to 1900 mtrs. approx.
 Run-away speed = 1.8 x rated speed approx.

 Francis:-
 Used for head H = 45 to 600 mtrs. approx.
 Run-away speed = 2.0 x rated speed approx.

 Kaplan:-
 Used for head H = 10 to 50 mtrs. approx.
 Run-away speed = 2.2 x rated speed approx.

 Bulb:-
 Used for head H <= 15 mtrs. approx.
III – Different Types
 Types of Generator

A) Salient poles generators

1. Low speed generators
2. High speed generators
3. Generators - Motors
4. Bulb generators
5. Small hydro generators
B) Cylindrical poles generators
1. Turbo generators
 Salient pole generator

Machines with salient poles:

Rotor

•Rotor with salient poles

•Rather slow machine (n < 1000 rpm)
Large number of poles Stator
Large diameter Da > 3 m
Limited length of the machine

Applications:

Hydraulic power plants

Salient pole generator

Drakensberg

280 MVA
375 rpm
16 poles
11 kV
Low Speed Generators

Merowe
(Turkey)
140 MVA
100 RPM
Low Speed Generators

Porto_Primavera
(Brasil)

112 MVA
75 rpm
96 poles
13.8 kV
High speed salient poles Generators

Afourer
192 MVA
750 RPM
 Generator - Motor

Huizhou
353 MVA
500 RPM

Generator - Motors
Bulb generators

Guigang
(China)

32.6 MVA
78.9 rpm
76 poles
10.5 kV
 Cylindrical Poles Generator

Turbo-generators: Rotor

• High speed machine (n >1000 rpm)

Limited pole number, 2 or 4 poles
Limited diameter Da # 1m Stator
Long machines
Cylindrical rotor

Applications:

Thermal power plant

Gas & combined power plant, …
 Introduction

Classification of Generators
2. CYLINDRICAL POLE MACHINE
1. SALIENT POLE MACHINE
-Field winding is distributed in slot of rotor
-Projected pole with concentrated field winding
lamination
-Used for low & medium speed Vertical hydro
-Used for High speed Turbo Generators
Generators

Salient pole
Cylindrical pole
Turbo Generator
IV - Main components of vertical hydro Gen.
Generator Pit
Upper
Bracket
Sole plate

Stator sole
Plate

Lower
Bracket sole
plate
 Main components of vertical hydro Gen.

View of a generator
Collector

Upper bracket
Guide bearing

Winding
Rotor shaft Frame
(upper part)
Rim
Rotor spider

Stator core

Air coolers Poles

Guide bearing
Rotor shaft
(Lower part) Thrust bearing
Lower bracket
 Stator Frame

Functions:-
 allow a good positioning of the magnetic core punching
 support the weight of the magnetic core, winding and
upper bracket
 allow stator handling
 take over the magnetic core clamping forces
 transmit the vertical loads, the normal and accidental torques
and also the radial forces to the foundations
 guide the cooling air towards the heat exchangers
 support the connections and terminals
 Stator Frame

Frame Stator Core Winding

Stator Frame - Subansiri

Data:
O.D =13770mm
No. of Feet =12
Height = 4500 mm
No. of segment = 4
 Stator Frame
Oblique elements
• ADVANCED TECHNOLOGY
STRUCTURAL DESIGN WITH OBLIQUE ELEMENTS

– Circularity, concentricity and stability is guaranteed under

any condition like thermal expansion, centrifugal forces,
shrinkage of rotor rim and forces due to fault disturbances
 Comparison
Les éléments obliques – Système breveté
 Oblique
Les éléments elements
obliques – Système breveté

a)
a)oblique
obliquesprings
springs
b,
b, c)
c)oblique
obliquearms
arms
b

a
a
c
c
 Stator Core

Function:-
To conduct magnetic flux lines to generate usefull
output power

- Thickness of lamination usually 0.35 or 0.5mm

- Coated on both sides by insulating varnish to reduce
magnetic losses

Maintenance free core pressing system

Stator core main components

Maintenance free core pressing system

 Stator Core Pressing System
Stator core pressing system with pre stressed studs passing
through core

 Prevent any buckling

or loosening of core
during whole life time.
 Complete pre-stress
force concentrated in core.
 High, uniform pressure
is ensured.
 No reaction on stator frame.
 Increased clamping elasticity
using spring washers.

VPI or Resin Rich Insulation system

 Stator Winding

Winding : The main function of winding is to generate voltage

when current flow from it.
Basically it includes Copper strips and Insulation
Requirement of Insulation:
• Temperature (high or low)
• Radiation
• Pressure waves, Vibration
• Humidity
• Magnetic fields
• Voltage, Current

VPI or Resin Rich Insulation system

 Stator Winding
Type of stator winding
1. Coil winding
2. Bar winding

Choice of type of stator winding

1. Coil winding :
- Gives more flexibility for electromagnetic design i.e. more design optimization may be possible.
- Manufacturing cost is lower
- Manufacturing difficult for coil height & width higher than 65 x 25 mm due to limitation of pulling machine
- Installation of stator coils are difficult if coil pitch is less than 35 mm
- Can be used up to current per circuit of 1500 A
- Low space factor

VPI or Resin Rich Insulation system

 Stator Winding

2. Bar winding
- Electrical design flexibility is low
- Useful when current per circuit is higher than 1500 A
- High space factor compare to coil winding
- Useful for deeper slots i.e. higher bar height
- Overall costly compare to coil winding due to roebelling by hand, requirement of insulating caps etc.
- Installation is easy

VPI or Resin Rich Insulation system

 Stator winding

Slot Wedge
Ripple Spring
 Bar or coil wrapped with
folded semi conductive foil.
Round  Foil with elastic silicon
Packer Packing compound between foil
Main sides.
Insulation
 Permanent electric and
mechanic coupling of the bar
Separator to the slot is guaranteed by
the “Round packing” system.
Corona
Shield
 Wedging with ripple spring.
Roebel
Transposition
Conductor

« Round packing » & ripple spring to avoid vibration in the slot.

 Rotor Spider - Rim - Poles

Spider Rim

Shaft Pole

(Tucurui - 5 units - rotor diameter 16m)

 Rotor Spider
Functions:-
 To transmit the motor or braking torques between the turbine
shaft and the rim
 To ensure the centering of the rim and the poles
 To withstand vertical loads due to the weight of poles, rim and
upper shaft
 To support the brake track and withstand its centrifugal forces
 To provide a passage for cooling air of rim ventilated units

Material:- Hot rolled steel plates

Increased reliability of the rotating parts: no interpolar “V” blocks are needed
 Rotor spider

Central Hub
Wedge carrier

Oblique Arm
 Rotor Rim

Functions:-
 To fix the field poles
 To ensure the magnetic flux path from one pole to the
neighbour
 To take part in the fan effect of the radial cooling of the
synchronous machine
 To transmit torque from center of machine to poles
 To contribute in providing the required inertia (GD2).
 To support other components like field leads, brake track,
leads etc.

Material:- Hot rolled steel plates

Thickness:- 2 to 4mm

Increased reliability of the rotating parts: no interpolar “V” blocks are needed
 Rotor Rim

• Main Components :
• Rim Lamination
• Rim End Plate Rim
• Lamination
Rim Stud Rim stud
• Rim Key Arragement

Increased reliability of the rotating parts: no interpolar “V” blocks are needed
 Rotor Pole & Pole Coil

Damper Segment Pole Sheet

Pole Coil
Damper bars
Pole Claw

Increased reliability of the rotating parts: no interpolar “V” blocks are needed
 Rotor Pole - Subansiri
Construction :

Increased reliability of the rotating parts: no interpolar “V” blocks are needed
 Rotor Pole

Increased reliability of the rotating parts: no interpolar “V” blocks are needed
Rotor poles with end plates
 Bearing & Bracket

Bearing Types :

• Thrust Bearing :
- To carry all vertical loads (Generator rotor wt. + Turbine wt) and
axial hydraulic thrust from turbine

• Guide Bearing :
- To keep Shaft line (Generator + Turbine) system in center
 Bearing & Bracket

Bracket
Guide Pad
Self-pump Guide pads
Working principle of Self-pump Guide pads
 Pad support: Spindle pad support
In this basic solution, an elastic height-adjustable thread
supports the bearing pads. This design is used for
medium-sized to large generators. Spindle design can
also be used in connection with double-layer bearing
pads.
Pad support: Spring-plate pad support
In this design, the bearing pads are supported from below
by a spring plate. This cost-effective and very compact
design is mainly used for small and medium-sized
generators.
 Pad support: membrane

Thrust Pad
 Oblique element structure
a = Connection stator / founda-
tion using oblique columns
b
b = Upper bearing bracket with
oblique arms

c = Lower thrust braket with

oblique arms
a
c
Bearing Arrangement
 Combined Bearing (Thrust & Guide)

Thrust
collar

Guide pad

Thrust pad

Bracket
V – Auxiliaries
 Auxiliaries

- Fire protection (spray water or CO2)

- Electrical / Mechanical braking system
- Bearings oil mist exhaust system
- Braking and collector dust exhausse system
- Monitoring (Vibrations, Partial Discharges, Air gap)
- High Pressure Oil System
- Generator Cooling
 Braking

Braking types
Electrical – applied at approx. 50% of rated speed
Mechanical – applied at 15% to 30% of rated speed
• Conventional i.e. Brake & Jack cylinder
• Disc brake which is mounted on the upper side of
generator
 Mechanical Braking

Conventional braking:-
• Braking track is generally mounted under the rim or
rotor spider.
• Machines where there is a reduced space available
to install the brake track under the rotor rim, it is
installed under the spider.
 Mechanical Braking

Disc brake
Main advantages of the disc type braking system are:
 the braking disc is in an enclosure separate from the
synchronous machine ventilation enclosure. Thus
there is no possibility of brake pad dust emission in
the generator enclosure
 the braking jaws are more easily accessible for
inspection and maintenance
 the wearing braking pads are relatively small parts
fitted into the braking jaws and are easier to be
replaced.
 Mechanical Braking
Disc Brake

Braking
disc

Braking
jaws
Auxiliaries: Braking system (jacks)
 Generator Cooling

Cooling:-
 Stator cooling
• Air-water cooler (IP54)
 Rotor cooling
• Axial-radial Fan –
Used for smaller machines, where diameter is < 5mtr.

• Rim –
Used for large machines
VI – Erection of Vertical Generator
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
 Site erection

Installation
sequences
VII – Excitation System
 Excitation system

2 kinds of excitation system

Static
Response time in nearly zero while in brushless it is 0.1%
Brushless
 generally more expensive but becomes cheaper than static
excitation system when rotating speed of the generator
increases.
No Carbon dust and no maintenance of carbon brushes
When rotating exciter fails, it is more difficult to repair than
static excitation system
 Static excitation system

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