A PROJECT WORK ON

GENERATOR COOLING SYSTEM

WORK CARRIED OUT AT
NTPC Limited –RAMAGUNDAM

By

R. SATHVIKA 20285A0243
V.AKHILA 20285A0263
G. SANTHOSH 20285A0251
M. MOUNIKA 20285A0228
K. VENU 20285A0210
N. RAKESH 20285A0236

Project submitted under the supervision of

Sri. M. RAVINDRA REDDY, Sr.Manager (Operation)

KAMALA INSTITUTE OF TECHNOLOGY & SCIENCE

Approved by AICTE, New Delhi | Affiliated to JNTU, Hyderabad|
Huzarabad, Karimnagar, Telangana - 505468

1
 “GENERATOR COOLING SYSTEM”
SUBMITTED BY

CERTIFICA TE

This is to certify that the “PROJECT WORK” report entitled

R. SATHVIKA 20285A0243
V.AKHILA 20285A0263
G. SANTHOSH 20285A0251
M. MOUNIKA 20285A0228
K. VENU 20285A0210
N. RAKESH 20285A0236

In partial fulfillment of academic requirement for the award of

B. Tech degree in “ELECTRICAL & ELECTRONIENGINEERING”

In

KAMALA INSTITUTE OF TECHNOLOGY & SCIENCE

Approved by AICTE, New Delhi | Affiliated to JNTU,Hyderabad |
Singapur (V), Huzurabad (M), Karimnagar, Telangana - 505468

PROJECT GUIDE EDC INCHARGE

M. RAVINDRA REDDY PRETHEEKSHA

Sr. Manager Sr. Manager
Operation Department HR Department

2
 ACKNOWLE DG E ME NT

We are grateful to Miss.V.SUPRITHA Assistant Professor in Electrical

Engineering in Kamala Institute of Technology & Science Singapur,
Huzurabad, Karimnagar(D) for their valuable suggestions,which helped
us during the project.

We express our thanks to project coordinator Sri. M.RAVINDRA

REDDY,Sr.Manager (Operation) for his valuable and timely suggestions
during our project.

We sincerely express our gratitude and respect to all those who

guided, inspired and helped us in successful completion of the project.

R. SATHVIKA
V. AKHILA
G. SANTHOSH
M. MOUNIKA
K. VENU
N. RAKESH

3
 DECLARATION

We are here by declare that the work

project
“ G EN ERATO R C O O LIN G SYSTEM ” is entitled out
carried
independently at “N.T.P.C Limited, Ramagundam” under the able
guidance of Sri. M.RAV INDRA REDDY, Sr.Manager by
(operation),
us
N .T.P.C . and M s.V .SUPRITHA Asst.Professor D epartment
of
Electrical and Electronics Engineering, Kamala Institute Of
Technology & Science, Singapur, Huzurabad, Karimnagar in partial
fulfillment of the requirement for the award of the degree of Bachelor
Of Technology in Electrical and Electronics Engineering by JNTU
University, Hyderabad.

R.SATHVIKA

V.AKHILA

G.SANTHOSH

M. MOUNIKA

K. VENU

N. RAKESH

4
 ABSTRACT

In the present scenario, power generation has changed drastically

because of increasing energy demand. Earlier days power generator
capacities were limited to 200MW. Later, it was increased to 500MW and
above.

With increase in demand, cooling system required for extraction of

heat produced in generator also changed. Today even 800 MW power
generators are available in the market, with advanced technologies of
cooling system.

In general any power generator has to supply its full rated capacity.
So, for a typical 500MW generator its rated terminal current is around
15000Amp. This huge current generates large quantity of heat in the
windings. This needs to be evacuated from the generator continuously.

In Ramagundam Super Thermal Power Station, BHEL make

500MW power generators are cooled by means of H 2 gas and Primary
water.

In this project, the cooling system of Generator stator and rotor is

presented for 500MW power generator.

5
 C ontents

S. No. Topic Description Page No.

01 Introduction to NTPC. 07
02 Details of NTPC – Ramagundam Super 10
Thermal Power Station.

03 Brief details of Thermal Power Plant 16

auxiliaries.

04 Principle & Operation of Generator. 28

05 Global developments and Designation. 29
06 Generator parts and Construction. 30
07 Necessity of cooling system for Generator 45
08 Hydrogen Gas cooling system of generator. 46
09 Primary water system. 56
10 Seal oil system. 69
11 Conclusion. 71
12 Reference and Bibliography 72

6
 Introduction to NTPC

Power is an important infrastructure in developing countries. Power

development in India received a big boost with the dawn of National Thermal
Power Corporation Limited.

NTPC was incorporated in 7th November 1975. In the last 39 years, it has
grown into the largest power utility of India. Based on 2014 data, carried out by
Forbes global NTPC is the 42nd rank in the world. NTPC was ranked 62nd among the
250 largest Power Producers and Energy Traders in the world by Platts in 2012. In
2009, it received ICSI National Award for Excellence in Corporate Governance.

NTPC is the largest thermal power generating company of India. A public

sector company, it was incorporated in the year 1975 to accelerate power
development in the country as a wholly owned company of the Government of
India.

NTPC has emerged as a truly national power company, with power

generating facilities in all the major regions of the country

NTPC, with an installed capacity of 43143 M W (from 39 different stations

spread throughout India) is generating 16.9% of India’s entire power requirement.
So, it is recognized as the India’s largest power utility with excellent core values.
Customer focuses organizational pride, mutual respect, initiative speed and total
quality.

7
NTPC Vision
"A world class integrated power major, powering India’s growth, with increasing
global presence"

NTPC Mission
"Develop and provide reliable power, related products and services at competitive
prices, integrating multiple energy sources with innovative and eco – friendly
technologies and contribute to society"

Core Values
 Business Ethics.
 Environmentally & economically sustainable.
 Customer focus.
 Organizational & Professional pride.
 Mutual Respect & Trust.
 Innovation and Speed.
 Total Quality Excellence.
 Transparent and Respected Organization.
 Enterprising.
 Devoted.

Leading In Power Sector

The RSTPS today rose like a phoenix. Skyline NTPC rides the rest of pride as
all the 7 units were commissioned ahead of schedule NTPC is also one of the

8
M A H A R AT N A corporation in public sector, has the generating capacity of 43143
MW, through its 17 coal and 7 gas based power projects situated at various parts of
the country. This account is almost 1/5th of the total generating capacity of the
country in all sectors put together. Thus every 5th bulb in the country is lit by NTPC
power.

NTPC has set new benchmarks for the power industry both in the area of
power plant construction and operation. It is providing power at the cheapest
average tariff in the country. With its experience and expertise in the power sector,
NTPC is extending consultancy services to various organizations in the power
business.

NTPC's core business is engineering, construction and operation of power

generating plants and also providing consultancy to power utilities in India and
abroad. As on date the installed capacity of NTPC is 43143 M W through its 17 coal
based (33015 MW), 7 gas based (4044 MW), 8 Renewable energy projects (110MW)
and 7 Joint Venture Projects (5974 MW).

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 Details of NTPC - Ramagundam

Ramagundam Super Thermal Power Station is a plant with switching station for
southern grid, distributing 400 KV, generating 2600 MW, having mines, and Rail
transport facility. Plant generating power in three stages. Stage – 1 with three units
of 200 M W capacities, Stage – 2 with three units of 500 M W capacities and Stage-3
with 500 M W capacity.

Approval of RSTPS

 RSTPS was declared by government of India in 1978.

 Late Sri Morarji Desai, the PM laid the foundation stone of RSTPS.
 RSTPS began commercial operation by 1983.

Capacity:

Total Capacity: 2600 M W

Stage I : 3X200MW
Stage II : 3X500MW
Stage III : 1X500 M W

Plant location & layout

10
 NTPC Ramagundam is located at latitude of 18-46E and longitude of 76-26N.

River Godavari flows west to east. The site is accessible to N H 7. The plant
occupies an area of 10,000 Acers. The reservoir that serves as the intake water source
for power is located at the south. The ash disposal area and the township are located
to the west and northwest respectively.

NTPC is the largest generating company in India presently lighting every

fifth bulb in the country, embarks on its most ambitious expansion plants. It aims to
be a 75,000 M W by 2017.

The NTPC at RSTPS generates power through three units of 200 M W each
and three of 500 M W each. The power generated here is used for domestic and
industrial purpose in Telangana, Andhra Pradesh and other neighboring states.
Percentage of the power utilized by different states as follows:

Situated in a sparingly populated area at Jyothinagar of Ramagundam

Municipal area in Karimnagar district of Telangana state. Ramagundam is selected
for establishing a thermal power plant as the site in having following facilities.

 Availability of well-flourished coal mines.

 Continuous water supply.
 Coal transport facilities.

Fuel Requirement

The entire requirement of coal for the plant was proposed to met from the
near by Singareni Collieries Mines, which are about 30 Km away from the plant the
mines were possessing about 1800 million tones of coal at the time of installation.

11
Water Requirement

At the time of making feasible report alternatives were consider for meeting
the water requirements of cooling water. A detailed study indicated that it would
not be possible to meet it through direct circulation. So a dam was proposed. The
Pochampad Dam later called as Sri Ram Sagar Project was built on river Godavari.

Ash Disposal

Large area of land is required for the disposal of the waste like coal ash been
generated from the plant is pumped a slurry form through the pipeline to the ash
pond at Kandupally (village), which is 5 Km away from the power station. The ash
disposal is utilized in various forms.

Environmental Control

Station is equipped with highly efficient ESP system and with tall chimney of
about 225 m height, effluent treatment plant was also installed for reuse of decant
ash water from ash pond.

12
 NTPC, R A M A G U N DA M PLANT

Salient Features
Installed capacity : 2600MW.

Unit sizes (present) : 3 x 200MW + 3 x 500 M W + 1 x 500 MW.

Transmission system : 2400 Ckt Km - 400 KV.

Source of coal : Singareni Collieries Corporation Limited.

Water source : Sri Ram Sagar Project.

Beneficiary states : AndhraPradesh, Tamilnadu, Kerala, Karnataka,

13
 Goa, Telangana & Pondichery.

Approved investments : Rs.1703.18 Crores.

Coal Consumption : Approx. 12.5 million tones per annum.

Total Transportation : Merry Go Round system of 22.4 km.

Total land : Approx. 10,000 Acers.

Ash disposal : Ash pond at Kundanpally (village).

Evacuation of power:

The power generated from station is evacuated through 10 no’s 400KV, 3 no’s
of 220KV and 2no’s of 132kv overhead transmission lines.

Distribution of Electricity:

Total capacity of Ramagundam NTPC is 2600MW of stages 1, 2 & 3

distributing electricity to following states in Megawatt.

STATE MW %
A N D H R A PRADESH & T E L A N G A NA 610 29%
TAMIL N A D U 470 22%
K A R NATA K A 345 16%
KERALA 245 12%
G OA 100 5%
PONDICHERRY 50 2%

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 Remaining 250MW can be used to any state, now being used in Andhra
Pradesh and Telangana.
Total capacity of stage - 3 is 500MW - distributing electricity to following
states in MW:

STATE MW %
AP & T E L A N GA NA 145.86 29%
TAM IL NADU 118.20 23%
K A R NATA K A 86.76 17%
KERALA 1.61 2%
PONDICHERRY 12.57 2.5%

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 Brief details of Thermal Power Plant Auxiliaries

Single line diagram of thermal power plant

COAL FROM
MINES POCHAMPAD
W CANAL
C
AIR C YC L E
A
M.G.R O T
Atmosphere RESERVIOR
A E

C.H.P. R
L
W.T.P
C
C Air Pre
P.A. F.D.
Crusher Y
Y Fan Fan
Heater D.M
C
C Condenser
L PLANT
Bunker Coal Coal mill
L E
Feeder
E
BOILER
ASH C YC L E
STEAM CYCLE Bottom Ash ASH
Ash Slurry POND
I.P.T. Re- H.P.T. Hopper PUMPS
- heater

E.S.P. E.S.P.
Hopper
Cond – LP
L.P.T. C.E.P. heaters
enser
DAETP ID Fan
CHIMNEY
R
G Y
Eco-
System
B B.F.P.
Deaer- nomizer
ator

Coal mill

The coal mill contains a pulverizer, which pulverizes or powder the 20 mm

size of coal given to it. The pulverizer is an electric motor driven rotating mechanical

16
guiding mechanism that crushes the coal between a roller and a bowl and various
types of hammer or impact grinding mills.

Ball mills are most successfully in the pulverization of very hard or abrasive
coals such as anthracite coal.

Primary air fan (PAF)

The primary air fans are used to transport the pulverized coal to the
respective coal nozzles at each coal elevation in the furnace. Similar to the FD fan the
primary air fan also heats the air in the primary air pre-heater (PAPH). The source of
heating in the PAPH is also the waste flow gas. There are two PA fans for each
boiler.

Forced draft fan (FDF)

This FD fan sucks air from atmosphere. Pressurizes it and sends it to furnace
prior sending it to furnace, the pressurized air is heated in secondary air pre-heater
(SAPH) the source of heating in SAPH is the hot flue gas, which is leaving from the
boiler. There are two Force Draft fans for each boiler. The pressurized hot air
generally called secondary air acts as a combustion medium in the furnace.

 Take air from atmosphere at ambient temperature to supply essentially all the
combustion air.
 Can either be sized to overcome all the boiler losses (pressurized firing) or just to
put the air in the furnace (balanced draft units).
 The system resistance includes losses in the cold air duct, air-heater, the hot air
duct and the wind box in the balanced draft units.

17
 Speeds vary between 600 to 1500 rpm.

Induced draft fans

 Used only in balanced draft units, these fans literally suck the gases out of the
furnace and throw them into the stack. Handle dirty gases at temperatures of 125
to 200 Deg.C.
 System resistance includes losses in the Furnace, super heaters, reheaters,
economizer, water wall screens, air heater, gas ducting and electrostatic
precipitators (the entire gas path).

Fuel oil piping

The primary fuel coal has an ignition temp of 540 degree’s C. So cannot be
ignited directly. So additional oil is used as start up fuel.

The fuel supply is from the common fuel oil supply system comprising a
pump, which will serve all units in the station. The fuel oil flow to the burners for
achieving initial ignition temp is supplied from this system through a fuel oil supply
line to a header in the furnace. The oil may be heavy oil used for firing the boiler up
to 20% M G R or the light oil used for start up low load generation of the boiler.

Fuel firing and igniter system

From the pulverized coal bin coal is conveyed by hot air injectors through
coal pipes to boiler coal burners of one tier or level at a horizontal angle into the
furnace to give a swirling action for powdered coal for proper mixing of coal
powder and also the incoming hot air from FD fans, to give the best combustion. If

18
the system does not have pulverized coal bin then coal powder is conveyed directly
to coal burners from pulverizes. Then generally one tier is fed by one pulverizer.
To provide sufficient combustion temperature in the furnace before spraying
powdered coal to catch fire or ignite, the furnace temperature is brought up by
spraying and burning light oil by means of igniter oil guns. Oil is used in a fine
spray, as oil can catch fire even in ambient temperature.

Alternatively gas is also used for ignition instead of oil, if available in plenty.
However in this case the igniter gun design differs. To ignite the ignition oil or gas,
an Electric High Tension spark in the path of oil or gas is used momentarily and
then the spark gun is withdrawn.

Furnace
The furnace takes coal from coal mill, oil from oil gun, and air from FD fans
respectively for the process of combustion. The furnace has four walls. The wind
boxes which allow air into the furnace, coal inlets, oil guns air all arranged at the
four corners of the walls of the furnace. There are igniters which are at the corners
ignite the oil air mixture by producing a high voltage spark.

Turbine
Turbine is shaft coupled to Generator; the turbine is divided into three
categories, which have same shaft coupling.

1) H PT (High Pressure Turbine).

2) IPT (Intermediate Pressure
3) LPT Turbine). (Low Pressure
Turbine).

19
 The steam from HPT is sent to reheater and then to the IPT, the expanded
steam is tapped and sent to LPT. Where the temp is 530 deg C and pressure
decreases to negative (-0.86kg/cm2).

Some quantity of steam is tapped from IPT, LPT and is used to heat the feed
water in LPH, HPH. The condensed steam from the turbine is directly sent to
DEAERATOR.

Condenser

The steam after expansion through the turbine goes through the condenser.
The condenser improves the efficiency of the power plant by decreasing the exhaust
pressure of the steam below atmosphere. Another advantage of condenser is that
condensed steam can be recovered and this provides a good source of pure feed
water to the boiler thereby reducing considerably the water softening plant capacity,
air and non-condensable gases are removed from the steam when it passes through
the condenser.

Condensate extraction pump

It is used to pressure the water and to raise water to deaerator level.

Low pressure heater

It is a three-stage heater in which the temperature of the feed water is
increased to 130 deg C. It is situated between the condensate extraction pump and
deaerator. The pressurized water from CEP passes through coils present inside this
LPH chamber for heating these coils the steam tapped from IPT & LPT is used. This
heat is exchanged between the steam and water inside the coils.

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Deaerator

If the pressure of steam in the condenser is negative (below atmosphere)

there is a chance of mixing atmosphere air with steam, which damages the turbine
blades therefore deaerator is used to separate atmospheric air. In deaerator water is
sprinkled from the top. Therefore the dissolved gases and atmosphere air separates.
This pure and gas less feed water is collected.

Boiler feed pump

Boiler feed pump takes feed water from deaerator and pressurizes to the
highest level in water circuit to about 200kg/cm2 and sends it to boiler through high
pressure heater (HPH).

High pressure heater

It is a two-stage pressure heater, in which the tapped steam from turbine is

used to heat the feed water in HPH, feed water flows in a coil in which steam is sent
in opposite direction of feed water such that heat exchange takes place. Feed water
regulating system (FRS) regulates the quality of feed water to be fed into the boiler.

Electro static precipitator

It consists of alternative plates and windings, which carry positive and

negative charges respectively. The positive plates are grounded. The potential that
exists across windings is 40 to 50KV.with this potential ash gets separated from flue
gases. This deposit on windings is hammered which causes fall of ash into hoppers
where it is mixed with water for disposal.

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Working principle of electrostatic precipitator

Of all the devices used for solid-gas separation, electrostatic precipitator finds
wide application because of its inherent advantage over all other devices.
Electrostatic precipitators can handle large volume of gases from which solid
particulates are to be removed. Their technical superiority lies in low pressure drop,
high efficiency for small particles size, and relatively easy removal of the collected
particulates.

There are four different steps in the process of precipitation:

i) Ionization of gases and charging of dust particles.
ii) Migration of the particle to the collector.
iii) Deposition of charged particles on the collecting surface.
iv) Dislodging of particles from the collecting surface.

The electrostatic precipitator essentially consists of two sets of electrodes, one

in the form of thin wires called discharge or emitting electrodes and other set called
collecting electrodes in the form of pipes or plates. The emitting electrodes are
placed in the centre of pipes or midway between two plates and are connected
usually to negative polarity of high voltage D C source of the order of 25-100kV.

The collecting electrodes are connected to the positive polarity of the source
and grounded. The high electric field in the vicinity of the emitting electrodes
creates ‘corona discharge’ ionizing the gas molecules.

22
 The dust particles entrained in the gas acquire negative charge and
experience a force which drives them toward the collecting electrodes where they
get deposited. The collected material is dislodged by knocking the electrode by a
process called ‘Rapping.’

The collection efficiency (h) of a precipitator is given by an empirical

formula.
- (WKSCA) 1/2=1 -e
Where W, K has the dimension of velocity and is known as migration
velocity
S CA is

Specific collecting electrode area = Total projected collecting area

Gas flow rate

This equation indic ates that higher collection efficiency can be obtained by
increasing the size of the precipitator or increasing the total collecting surface area.

The migration velocity, WK is influenced by the electrical power input,

electrical resistivity of the dust particles, dust burden, grain size distribution,
temperature. This value varies from 15cms/sec. to 50cms/sec. Depending on the
collection
efficiency requirement, specific m2/m2/sec.

Generator

The generator is one of the important blocks in the power production plant.
Generator is coupled with turbine, which rotates due to the steam. The generator
consists of two important parts namely the stator and the rotor. The stator consists
of windings to generate electric flux with the help of an excitation unit provided.
The rotor is the rotating part, which is coupled to the shaft with bearings.

23
 The rotor is a conductor and as a conductor is cutting the flux an E.M.F is
induced which is tapped as power supply. Thus the steam energy is converted into
electric supply. This supply is 22KV voltage is increased to 400KV for transmission
purpose by using a step-up transformer.

Technical Specifications of RSTPS Generator and Exciter

Generator

(a) Make : BHEL

(b) Type : ELR 70/90-30/6-20 THDF 115/59
(c) Duty : S1
(d) Insulation class :F
(e) Cooling of stator winding : Directly water cooled
(f) Cooling of stator core & rotor : Directly hydrogen cooled

Rated Data

(a) Apparent Power : 588 M VA

(b) Active power : 500 M W
(c) Current : 16200 Amps.
(d) Voltage : 21 KV  1.05 K V
(e) Speed : 3000 rpm
(f) Frequency : 50 H z
(g) Power Factor : 0.85 (lag)
(h) H2 pressure : 4.0 bar
(i) Cont. perm. Unbalance load : 8%
(j) Rated Field current for rated output : 4040 A
(k) Rated Field Voltage :
340 V
(l) Inner connection of stator winding :
YY
= 0.001392 ohms
(m) No. of terminals brought out :6
• V-Y = 0.001388 ohms
(n) Stator winding resistance at 20oC 24 :
•U-X W-Z = 0.001385 ohms
Main Exciter

(a) Active Power : 3780 KW

(b) Current : 6300 AMP.
(c) Voltage : 600 V
(d) Speed : 3000 rpm
(e) Stator winding resistance at 20oC : F1-F2 = 0.57422 ohms
(f) Rotor winding resistance at 20oC : U-V = 0.0004244 ohms
• U-W = 0.0004244 ohms
• V-W = 0.0004244 ohms

Rectifier Wheel

(a) No. of wheels : 2 (one positive and one negative)

(b) No. of Fuses per rectifier wheel : 30
(c) Fuse resistance : Approx. 150 Micro ohms
(d) No. of diodes per rectifier wheel : 60.

Pilot Exciter

(a) Apparent Power : 65 KVA

(b) Current : 195 A
(c) Voltage : 220 V  22 V
(d) Speed : 3000 rpm
(e) Frequency : 400 H z

25
(f) Stator winding resistance at 20oC : U-O = 0.002518 ohms
• V-O = 0.002538 ohms
• W-O = 0.002529 ohms

Exciter Air Dryer

(a) Type : BA-1.5 A

(b) Rating : 1.28 KW
(c) Voltage : 240 V
(d) Frequency : 50 H z
(e) Adsorption air Flow rate : 120 m 3/h
(f) Regeneration air Flow rate : 35 m 3/h
(g) No. of dryer : 1 N o.

Torque / Critical
Speeds

(a)Max. Short circuit torque of stator : 14585 knm

at line to line single phase short ckt.
(b) Moment of inertia of generator : 10000 kgm 2
shaft
: nk114.4S-1 (V-Gen), nk2 30.1 S-1
(c) Critical speed (calculated)
(V-Exc) and nk3 39.8S-1 (S-
Gen)

Generator volume and Filling quantities

(a) Generator volume (gas volume) : 80 m 3

(b) CO2 Filling quantity : 160 m3 (S.T.P.)*

26
(c) H 2 Filling quantity (To 4.0 bar) : 480 m3 (S.T.P.)*

S.T.P. = Standard temperature and Pressure, 0 o C and 1.013 bar to DIN 1343

CO O L I N G TOWER :-
The cooling tower rejects waste heat from the steam cycle to atmosphere. A
cooling tower is a specialized heat exchanger in which two fluids (air water) are
brought into direct contact with each other to affect the transfer of heat. In a "spray-
filled" tower, this is accomplished by spraying a flowing mass of water into a rain-
like pattern, through which an upward moving mass flow of coal air induced by the
action of a fan or by natural draft.

A S H H A N D L I N G SYSTEM

In ash handling system there are bottom ash &fly ash system about 80%of
total ash is coming as fly ash is collected in ESP. 20% of ash as bottom ash is
collected at the bottom of the furnace. The fused ash will fall at the bottom
&quenched in water. So, formed clinkers are grinded in clinker grinder & the
powder will be mixed with water &flushed out to pump house from where it is
pumped out to ash pound.

The bottom ash hopper is of H2O impounded self supplying type located
directly beneath the boiler. This is periodically removed.

AIR & FLUE G A S SYSTEM

RSTPP boiler is of balanced draft system plus set of FD and ID fans are used
to maintain a vacuum inside the furnace. Air system starts with the FD fans. They

27
suck the air from the atmosphere &deliver to RAPH. The hot air will be supplied to
the PA fans. Flue gas system starts from the furnace. The ID fan will suck the hot
flue gas through the air preheater & ESP &deliver to the stack.

Air supplied inside the furnace, which is above theoretically calculated

required value for complete combustion, is called as excess air. To have a proper
combustion we should always maintain some percent of excess air. If the excess air
increases this leads to disadvantages.

Principle & operation of generators

An electrical generator is a device that produces electrical energy from a
mechanical energy source. The process is known as electricity generation.

Working principle:

Michael Faraday discovered that a potential difference is generated between

the ends of an electrical conductor that moves perpendicular to a magnetic field. He
also built the first electromagnetic generator called the Faraday disc, a type of
homopolar generator, using a copper disc rotating between the poles of a horseshoe
magnet. It produced a small direct current of electricity.

The A.C. generator or alternator is based upon the principle of

Electromagnetic induction and consists generally of stationary part called stator and
a rotating part is called rotor. The stator houses the armature windings. The rotor
houses the field winding. D C voltage is applied to the field winding. When rotor is
rotated, the lines of magnetic (i.e. magnetic field) cut through the stator windings.
This includes an Electromotive force in the stator windings.

28
Maximum power:

The maximum power theorem applies to generators as it does to any source

of electrical energy. This theorem states that the maximum power can be obtained
from the generator by making the resistance of the load equal to that of the
generator. However, under this condition the power transfer efficiency is only 50%,
which means that half the power generated is wasted as heat inside the generator.
For this reason, practical generators are not usually designed to operate at maximum
power output, but at a lower power output where efficiency is greater.

Global development

 First single phase generator of 75 KW 1888

 First 3 phase generator, salient pole 1900
 First turbo type 3 phase 25 M W generator 1912
 CEA, U K made 50 H Z as standard frequency for Europe 1925
 First Hydrogen cooled 3 phase 30 M W generator 1937
 First Hydrogen cooled TG with direct cooling of rotor 1949
 First generator with water cooled stator winding 1956
 First generator with water cooling for stator and rotor winding 1959

Generator Designation

29
 THFF
THD
THDD
THRI
TLRI
TLII

1 2 3 4 5 6 8 10 20 30 40 50 100 200
Generator rating in
Air Hydrogen
Water
The letter symbol of the Generator type designation The third letter designates the type of cooling of the
consists of four capital letters denoting the following. rotor winding
R = Direct radial gas cooling.
The first letter designates the product. D = Direct axial cooling.
F = Direct water cooling.
T = Three Phase Turbo Generator
The second letter designates the cooling gas in the The fourth letter designates the type of cooling of the
generator housing. Stator winding.
I = Indirect gas cooling.
L = AIR D = Direct gas cooling.
H = Hydrogen F = Direct Water cooling

Generator Parts and Construction

Components of Generator:
The main components of a generator are:

1. Stator
 Stator frame
 End shields
 Stator Core
 Stator winding
 Hydrogen coolers

30
 2. Rotor
 Rotor shaft
 Rotor windings
 Rotor retaining rings
 Field connections

3. Bearings.
4. Shaft Seals.
5. Excitation System.

Main Parts of Turbo Generator

Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing

General Description:

The two-pole generator uses direct water cooling for stator winding. Phase

31
connectors and bushings and direct hydrogen cooling for the rotor winding. The
losses in the remaining generator components, such as iron losses winding losses,
and stray losses, are also dissipated through hydrogen.

The generator frame is pressure resistant and tight and equipped with one
stator end shield on either side. The hydrogen coolers are arranged vertically inside
the turbine end stator end shield

Stato
Stator Frame r

It consists of a cylindrical center section and two end shields which are gas
tight and pressure resistant. The stator end shields are joined and sealed to the stator
frame with an O-ring and bolted flange connections. The Stator frame
accommodates the electrically active part of stator i.e., the stator core and windings.
Both the gas ducts and large number of welded circular grips provide for the
rigidity of the stator frame. Ring shaped supports for resilient core suspension are
arranged between circular ribs. Feeds are welded to the stator frame and end
shields to support the stator on the foundation.

32
 Stator Frame Interior

C lamp Dovetail bar

Frame Supporting Ring
H ousing

33
 Stator Frame - outside

Stator end Frame Stator foot

Shield H ousing
Bu
s
Compartment
h
i
Stator Core n
g

It is stacked from insulated electrical sheet steel laminations and mounted in

supporting rings over insulated dovetailed guide bars. Axial compression of the
stator core is obtained by clamping fingers, pressure plates and non magnetic

34
trough-type clamping bolts which are insulated from the core. The supporting rings
from part of an inner frame cage.

This cage is suspended in outer frame by a large number of separate. Flat

springs distributed over the entire core length. The flat springs are tangentially
arranged on the circumference in sets with three spring each, i.e., two vertical
supporting on both sides of the core. The horizontal stabilizing springs below the
core.

The springs are so arranged and tuned that forced vibrations of the core
resulting from the magnetic field will not be transmitted to the frame and
foundation.

The pressure plates and end portions of the stator core effectively shielded
against stray magnetic fields. The flux shields are cooled by a flow of hydrogen gas
directly over the assembly.

Clamping finger

Stator slow
Pressure
plate

Stator core tooth

Clamping bolt

Segment with spacers Stator core after compression Shield

35
Stator End shields

 The ends of the stator frame are closed by pressure containing end shields.

 The end shields feature a high stiffness and accommodate the generator
bearings, shaft seals and hydrogen coolers.
 The end shields are horizontally split to allow for assembly.
 The end shields contain the generator bearings.

36
Stator windings:

 Stator windings should be designed to carry full load current without

overheating.
 Insulation should be sufficient to prevent any leakage currents.
 Slots are provided on the inner periphery and windings are placed in these slots.
 3 Phase, fractional pitch, two layer lap winding.
 Each phase may have one or more parallel paths.
 Each Conductor is made up of number of rectangular sub conductors.
 Each sub conductor is insulated from each other by insulation.
 Conductors are transposed over 540 degrees over the entire length of the core.
(To avoid skin effect losses).
 This is done to reduce eddy current losses.
 One turn of the conductor consists of two conductors joined together at the end.
 Two conductors per slot.
 Micalastic insulation is used for conductor’s insulation.

 High-quality mica, selected epoxy resins and a matching vacuum impregnation

process are the characteristic features of the Micalastic insulation for large turbo
generators.
 To prevent corona discharge the conductors are coated with semi conducting
paint like a thin layer of graphite.
 Stator conductors are secured in slots by strong wedges.
 End winding should be rigid to withstand stresses those are arising at the time of
short circuit.
 In 500 M W units conductors are water cooled.
 Hollow conductors are placed in the slots through which water will flow thereby
cooling the conductors.

37
Hydrogen coolers

The hydrogen cooler is shell and tube type heat exchanger which cools the
hydrogen gas in the generator. The heat removed from the hydrogen is dissipated
through the cooling water. The cooling water flows through the tubes. While the
hydrogen is passed around the finned tubes.

38
 The hydrogen flows through the coolers in a horizontal direction. The cold
cooling water flows from the bottom to the top of the cooler on the cold gas side
and, after reversal in the return water channel, the heated water flows downwards
on the hot gas side. This cooling water flow passage is obtained through a partition
in the inlet/outlet water channel.

Each cooler consists of the tube bundle, the upper and lower tube-sheets, the
return water channel and the inlet/outlet water channel. The tubes have copper fins
to obtain a larger heat transfer surface, the fins being joined to the tubes by tinning.

The ends of the tubes are expanded into the upper and lower tube-sheets. The
two side walls of structural steel base the cooler and direct the hydrogen flow. They
are solidly bolted to the upper tube-sheet. While the attachment to the lower tube
sheet permits them to move freely to allow for expansion of the tube bundle.

Flexible seal strips bolted to the side walls seal the gap between the cooler
and the cooler well in the cooler assembly, thus preventing uncooled hydrogen from
flowing past the cooler.

The upper tube sheet is larger than the cooler well opening and is used to fix
the cooler. Gastight sealing of this tube sheet is done by a packing. The return water
channel is bolted to the upper tube sheet over a flat gasket.

This arrangement permits the return water channel to be detached for

cleaning, even when the generator is in operation and filled with hydrogen.

The lower tube sheet is freely movable and capable of following the
differential movement between stator frame and cooler due to the different thermal
expansion resulting from the different materials and temperature. Attached to the

39
lower tube sheet is the inlet/outlet water channel with its cooling water inlet and
outlet pipes.

A seal cap is bolted over the inlet/outlet water channel. The seal cap has
opening for bringing out the cooling water pipes. Gastight sealing is done by a gland
type seal which is simultaneously pressed against the outer circumference of the
tube sheet and against the sealing face of the seal cap by a compression ring.

The cooler are parallel-connected on their water sides shut off valves are
installed in the lines before and after each cooler. The required cooling water
volumetric flow depends on the generator output and is adjusted by a control valves
on the heated water side. Controlling the cooling water flow on the outlet side
ensures an uninterrupted water flow through the coolers.

40
 Coolers Specification

Design Data for the H 2 Cooler, (4

Units Materials and Pressures
x 25% each)
Hydrogen pressure 3.5 Bar (g)
Gas flow (Total) 33 m3 /s
Heat dissipating capacity (Rated) 4640 kW Materials Fins Copper Tubes
90/10 Cu-Ni Tube sheets
Cold gas temperature 44 °C Carbon steel Water channels
Hot gas temperature (max.) 72 °C Carbon steel Pressures (Tube
Gas pressure drop (approx.) 700 Pa Side) Design pressure 10
Cooling water flow (Total for 4 kg/cm 2 Test pressure 15
540 m3 /hr kg/cm 2
sections)
Cooling water inlet temperature
38 °C
(design)
Water outlet temperature 45.4 °C
Water pressure drop 3.2 M WC

Roto
Rotor shaft:
r

The rotor shaft is a single-piece solid forging manufactured from a vacuum

casing. Slots for insertion of the field winding are milled in to the rotor body. The
longitudinal slots are distributed over circumference so two solid poles are obtained.
The rotor poles designed with transverse slots to reduce twice system frequency
rotor vibrations caused by deflections in direction of the pole and neutral axis.

To ensure that only high quality forgings are used strength tests, material
analysis, and ultrasonic tests are performed during manufacturing of the rotor.

After completion, the rotor is balanced various planes at different speeds and
then subjected to an over speed test at 120% of rated speed for two minutes.

41
 Rotor shaft

Shaft Rotor slot Transverse slot Retaining

Journal In pole Ring seat
Rotor tooth
Pole

Rotor winding:

 The field winding consists of several coils inserted into the longitudinal slots
of the rotor body.
 The coils are wound around the poles so that one north and one south
magnetic pole are obtained.
 The hollow conductors have a trapezoidal cross section and are provided
with two cooling ducts of approximately semi-circular cross-section.
 All conductors have identical copper and cooling duct cross-sections.
 The conductors are made of copper with a silver content of approximately
0.1%.
 The insulation between the individual turns is made of layers of glass fibre

42
 laminate.
 To protect the winding against the effects of the centrifugal force, the winding
is secured in the slots with wedges.
 The slot wedges are made from a copper-nickel-silicon alloy featuring high
strength and good electrical conductivity, and are used as damper winding
bar.

Construction
It consists of several coils inserted into the longitudinal slots of the rotor body
the coils are wound around the pole so that one north and south magnetic pole are
obtained.

The hollow conductors have a trapezoidal cross section and provided with
two cooling ducts approximately semicircular cross section. All conductors have
identical copper and cooling duct cross sections.

The individual conductors are bent to obtain half turns. After inter section
into the rotor slots these turns are combined to form full turns ,the series connected
turns of one slot constituting one coil the individual coils of the rotor winding are
electrically series connected.

Retaining rings

The centrifugal forces of the rotor end windings retaining rings. The retaining
rings are made of non-magnetic high-strength steel in order to reduce stray losses.
Each retaining ring with its shrink-fitted insert ring is shrunk on to the rotor body in
an overhung position. The retaining ring is secured in the axial position by a snap
ring.

43
Field connections

The field current is supplied to the rotor winding through a radial terminal
bolts and two semi conductors located in hallow bores of the exciter and rotor shaft.
The field current leads are connected to the exciter leads at the exciter coupling with
multi contact plug-in contacts which allow for unobstructed thermal expansion of
the field current leads.

Rotor Axial Fan

 The generator cooling gas is circulated by one axial-flow fan located on the
turbine-end shaft journal.
 To augment the cooling of the rotor winding, the pressure established by the
fan works in conjunction with the gas expelled from the discharge ports along
the rotor.

Generator Bearings

 The rotor shaft is supported in sleeve bearings having forced-oil lubrication.

 The bearings are located in the stator end shields.
 The oil required for bearing lubrication and cooling is obtained from the
turbine oil supply system and supplied to the lubricating gap via pipes
permanently installed inside the lower half of the stator end shield and via
grooves in the bearing saddle and lower bearing sleeve.

Shaft Seals
 The rotor shaft ends are brought out of the gastight enclosure through double-
flow shaft seals.

44
 With this type of shaft seal, the escape of hydrogen between the rotating shaft
and the housing is prevented by maintaining a continuous film of oil between
the shaft and a non-rotating floating seal ring.
 To accomplish this, seal oil from two separate circuits, i.e. the air side and the
hydrogen side seal oil circuit, is fed to the seal ring at a pressure slightly
higher than the hydrogen pressure.
 In addition, higher pressure air side oil is supplied to the shaft seal for thrust
load compensation of the seal ring.

45
 Necessity of cooling system for Generator

 Losses produced in the core and conductors are converted to heat, which
raises the temperature of parts of the generator.
 Cooling system takes care of this temperature rise and keeps the temperature
within the limits imposed by insulation properties of windings.
 Today large Generators are using Hydrogen as coolant maintained at a
pressure in the casing of the generator.
 Stator conductors are cooled by water flowing through the conductors.

The Heat will generate in the Generator due to:

 Copper losses in the Conductors.

 Eddy current and Hysterisis Losses in the stator and Rotor.
 Friction and Windage losses due to rotation.
 Hence proper cooling system is required to abstract the heat from generator.

46
 Hydrogen Gas cooling system of generator.

Advantages of Hydrogen Cooling

 High heat transfer coefficient. (1.5 times of air).

 High thermal conductivity. (7 times that of air).
 Lighter in weight so lesser windage & ventilation loss. (Density 0.07 times
that of air).
 Higher efficiency.
 Better cooling gives better life of insulation.
 Less noise.
 Size of machine & that of cooler gets reduced.

Disadvantage of Hydrogen

 Hydrogen is extremely flammable in air (flammability limits 4% to 75% by

volume). The energy required to ignite it is extremely small.
 Hydrogen burns in air with an almost invisible flame that emits very little
radiant heat and therefore gives limited warning of its presence.
 Hydrogen can diffuse rapidly through materials and systems that are leak-
tight to air or other common gases. Diffusion is more pronounced at elevated
temperatures.
 A comprehensive gas control is required.

47
Hydrogen cooling circuit

The hydrogen is circulated in the generator interior in a closed circuit by one

multi-stage axial-flow fan arranged on the rotor at the turbine end. Hot gas is drawn
by fan from the air gap delivered to the coolers, where it is re-cooled then divided
into three flow paths after each cooler.

Flow path I

It is desired into the rotor at turbine end below the fan hub for cooling of the
turbine end half of the rotor.

Flow path II

It is directed from the coolers to the individual frame compartments for

cooling of stator core.

Flow path III

It is directed to the stator end winding space at the exciter end through guide
ducts in the frame for cooling of the exciter end half of the rotor and of the core end
portions.

The three flows mix in the air gaps. The gas then returned to the coolers by
axial flow fan.

The cooling water flow through the hydrogen coolers

should be

48
automatically controlled to maintain a uniform generator temperature level for
various loads and cold water temperatures.

Ventilation diagram

Cooling of rotor

For direct cooling of the rotor winding, coal gas is directed to the rotor end
windings at the turbine and exciter ends. The rotor winding is symmetrical relative
to the generator center line and pole axis .Each coil quarter is divided into two
cooling zones.

The first cooling zone consists of the rotor end windings and the second one
of the winding portion between the rotor body end and the midpoint of the rotor.
Cold gas is directed to each cooling zone through separate openings directly before
the rotor body end. The hydrogen flows through each such that approximately

49
identical temperatures are obtained for all conductors.

The gas of the first cooling zone is discharged from the coils at the pole centre
into a collecting compartment with in the pole area below the end winding. From
there the hot gas passes into the air gap through pole phase slots at the end of the
rotor body. The hot gas of the second cooling zone is discharged into the air gap at
mid length of the rotor body through radial openings in the hollow conductors and
wedges.

Cooling of stator core

For cooling the stator core cold is admitted to the individual frame
compartments via separate cooling gas ducts.

From these frame compartments the gas then flows into the air gap through
slots in the core where it absorbs the heat from the core .To dissipate the higher
losses in the core ends, the cooling gas slots are closely spaced in the core end
sections to ensure effective cooling. These ventilating ducts are supplied with
cooling gas directly from the end winding space .Another flow path is directed from
the stator end winding space past the clamping fingers between the pressure plate
and core end section into the air gap. A further flow path passes into the air gap
along either side of the flux shield.

All the flows mix in the air gap and cool the rotor body and cool the rotor
body and stator bore surface. The gas is then returned to the coolers via the axial-
flow fan. To ensure that the cold gas directed to the exciter end cannot be directly
discharged into the air gap, an air gap choke is arranged with in the range of the
stator end winding cove and the rotor retaining at the exciter end.

50
Generator Gas System

The gas system contains all equipment necessary for filling the generator with

C O 2 , hydrogen or air and removal of these media, and for operation of the generator filled with

hydrogen. In addition, the gas system includes a nitrogen (N2) supply.

The gas system consists of:

 H 2 supply.
 C O 2 supply.
 Compressed Air supply.
 Pressure reducers.
 Pressure gauges.
 Miscellaneous shutoff valves.
 Purity metering equipment.
 Gas dryer.

 C O 2 flash evaporator.
 Flow meters.

51
1 – H2 Bottle.
2– H2 Pressure Reducer 13 – Dehydrating filter
3 – N2 Bottle For measuring gas.
4 – N 2 Pressure 14 – Pressure reducer for
Reducer 5 – Primary Measuring gas
water Tank 6 – 15– Compressed air hose
Pressure Controller 7 – 16 – Compressed air
Upper Gen gas header filter.
8– Lower Gen gas 17 – C O 2
header Flash
9– Gas drier heater evaporator.
10 – Gas drier fan

Gas system – Simplified

Hydrogen (H2) Supply

The heat losses arising in the generator are dissipated through hydrogen. For
more effective cooling, the hydrogen in the generator is pressurized.

The hydrogen gas shall be made available with purity of 99.9%. The
remaining 0.1 % shall be free of corrosive contaminants: traces of ammonia (NH3)
and sulpher dioxide (SO2) shall not be detectable by analysis.

If obtained from a central bulk supply, the hydrogen gas shall be made
available at the following conditions:

52
Gauge pressure: 8 to 9 bar
Volumetric flow rate: 144 to 216 m 3 /h.

Carbon Dioxide (CO2) Supply

As a precaution against explosive hydrogen air mixtures, the generator must

be filled with an inert gas (CO 2) prior to H 2 filling and H 2 removal. The generator must be filled

with C O 2 until it is positively ensured that no explosive mixture will form during the
subsequent filling or emptying procedures.

Carbon dioxide shall be made available with a purity ≥99.9 %. The

remaining
0.1 % shall be free of corrosive contaminants: traces of ammonia (NH3) and
sulpher dioxide (SO2) shall not be detectable by analysis.

If obtained from a central bulk supply, the gas shall be made available at the
following conditions:

Gauge pressure: 1 to 2.5 bar

Temperature: 20 to 30 0 C
Volumetric flow rate: 144 to 216 m 3 /h.

Compressed Air Supply

To remove C O 2 from the generator, compressed air is to be admitted into the generator.

The compressed air must be clean and dry. For this reason, a compressed air filter is
installed in the filter line.
The compressed air shall be free of corrosive contaminants and hazardous
gases, flammable or toxic. The maximum total oil or hydrocarbon content, exclusive
53
of non-condensable, shall be as close to zero (0) w/w or v/v as possible, and
under
no circumstances shall it exceed one (1) ppm w/w or v/v under normal operating
conditions.

The compressed air shall be practically free of dust. The maximum particle
size in the air stream shall be five (5) micrometers. The oxygen content of the
expanded air shall be between 20 and 21% v/v.

The dew point at line pressure shall be at least 15 K below the minimum
possible generator temperature. In no case should the dew point at line pressure
exceed 10 °C.

The compressed air shall be available at a gauge pressure between 6 and 9

bar. Volumetric flow rate: 144 to 216 m 3 /h.

Electrical Purity meter System:

 The transmitter for the CO2 / H2 purity meter system on the gas valve rack is
also of an explosion proof design.
 The meter system operates on the thermal conductivity method.
 The meter system measures the H2 content of the gas in the generator as well
as the composition of gas mixtures (CO2 / air and H2 / CO2) during filling
and emptying of the generator.

Mechanical Purity Meter System:

 The second purity meter system is a mechanical type and uses the physical
relationships between the hydrogen pressure, the speed of the generator fan,
and the specific gravity of the medium.
 This meter system, therefore, functions only at rated speed.

54
Technical Data - Gas System

Design Data
CO2 vaporizer
Rating 18 kW
Voltage 415V, 3 Ph A C 50Hz
Heat transfer liquid HYTHERM 500 (M/s HPCL)
Volume of heat transfer liquid 25 dm3
Hole in orifice 2.8 mm
Relief valve on high-pressure side 175 bar
Relief valve on low-pressure side 8 bar
Nos. 2x100% capacity

Compressed air filter

Volume of activated carbon 3 dm3
Service hours Approx. 1500 h to 2000 h
Throughput 80 m3 /hr at 8 bar
Nos. 1x100% capacity

CO 2 Flash Evaporator

 Since the C O 2 is available in the liquid state, it must be expanded into a gas before use.

The C O 2 is expanded in a C O 2 vaporizer located on the gas valve rack.

 To prevent icing of the vaporizer it is electrically heated.

 A temperature control is provided so that freezing of the flash evaporator is

prevented, and the C O 2 is admitted into the generator at the proper temperature.

55
Gas Dryer (Refrigeration Type)

For hydrogen gas drying, 2 nos. Refrigeration gas driers are available. Either
of these two can be selected for the gas drying operation, by suitably operating the
following valves, to bring in circuit either drier-1 or drier-2.

The Refrigeration gas drier is to be operated for a total period of 8 hours in 24

hours duration. This can be suitably selected on the timer available on the drier.

After the operation of the Refrigeration drier, the condensate gets collected in
the condensate chamber, which can be observed through the glass window. Drain
the condensate chamber once every 24 hours.

56
 Primary Water System

The primary water required for cooling is circulated in a closed circuit by a

separate pump. To ensure uninterrupted generator operation, two full capacity
pumps are provided. In the event of a failure of one pump, the standby pump is
immediately ready for service and cuts in automatically.

Each pump is driven by a separate motor. All valves, pipes and instruments
coming into contact with the primary water are made from stainless steel material.
The primary water system consists of the following principal components:

 Primary water tank.

 Primary water pumps.
 Cooler.
 Primary water filter.
 Fine filter.
 Ion exchanger.
 Alkalyser unit.

As illustrated in the primary water scheme, the primary water admitted to

the pump from the tank is first passed via the cooler and fine filter to the water
manifold in the generator interior and then to the bushings.

After having performed its cooling function, the water is returned to the
primary water tank. The gas pressure above the water level in the primary water
tank is maintained constant by a pressure regulator.

57
 Primary Water Scheme

PW TAN K
EXCESS G A S TO ATMO THRO. PRV
PW INLET TO STATOR W IN DIN G
Filte
r S Stroke adjustment
Generato PUMP&
M O TO R Ion Exchanger

N aoH
Tank
Fine Filter
Bushing A L KALISER
Outlet Bushing
Inlet

Flow meter
ECW OUT

Pr. Reg
PWP#1

M
PW Inlet C
ag
oo
PWP#2
N2 ne
le
Cylinder
tic

Fil
D M Make
To Ion
Up line PW Outlet te
Flow Exchange
mete r ECW INr
r
Temp C V

Primary Water Tank

The primary water tank is located on top of the stator frame on an elastic
support, thus forming the highest point of the entire primary water circuit in terms
of static head.

58
Primary cooling water circuit in the Generator

 The treated water used for cooling of the stator winding phase connectors
and bushings is designated as primary water in order to distinguish it from
the secondary coolant (raw water, condensate, etc.).
 The primary water is circulated in a closed circuit and dissipates the absorbed
heat to the secondary cooling water in the primary water cooler.
 The pump is supplied with hot primary water from the primary water tank
and delivers the water to the generator via the coolers. The cooled water flow
is divided into two flow paths.

Flow path 1:-

 Cools the stator windings. This flow path first passes to a water manifold on
the exciter end to the generator and from there to the stator bars via insulated
hoses. Each individual bar is connected to the manifold by a separate hose.
Inside the bars the cooling water flows through hollow strands.
 At the turbine end, the water is passed through similar hoses to another
water manifold and then returned to the primary water tank.

Flow path 2:-

 Cools the phase connectors and bushings. The bushings and phase connectors
consist of thick-walled copper tubes through which the cooling water is
circulated.
 The six bushings and the phase connectors arranged in a circle around the
stator end winding are hydraulically interconnected so that three parallel
flow paths are obtained.

59
 The primary water enters three bushings and exists from the three remaining
Bushings.
 The secondary water flow through the primary water cooler should be
controlled automatically to maintain a uniform generator temperature level
for various loads and cold water temperatures.

Pressure
Primary Water Tank Regulato Waste gas to
r A tmospher
e
Cooling Water
Manifold Teflon hose Cooling water to
Stator winding

Stator Winding
Pump
T E
Rotor

Cooler

Hydrogen Gas Io
n
Ex
Teflon hose
ch
Cooling water to main bushings
and phase connectors an
C ooling Water
Manifold Filter
Bypass line

Flow Path - I Flow Path - II

60
Electrical Bar Connection and Water Supply

1 Teflon Hose 8 C lamping plate with through

2 Crimping sleeve bore 9 Intermediate members
3 Cap nut 10 C lamping plate with threaded
4 Pipe connections bore 11 Bottom bar
5 Water box 12Top bars
6 Clamping bolt 13Belleville washers
7 Connecting sleeve

Primary Water Treatment System

The direct contact between the primary water and the high-voltage windings
calls for a low conductivity of the primary water. During operation, the electrical
conductivity should be maintained below a value of approximately 1 μmho/cm.

In order to maintain such a low conductivity it is necessary to provide for

continuous water treatment. During operation, a small quantity of the primary
water flow should therefore be continuously passed through the ion exchanger
located in the bypass of the main cooling circuit.

61
 The ion exchanger resin material required replacement during operation of
the generator, since with the water treatment system out of service, the conductivity
will rise very slowly.

Primary Water Specification – Quality to be maintained

The water used must not contain any contaminants that might have a harmful
effect on the materials used in the primary water circuit. For this reason, the water
must have the following quality criteria:

Conductivity: < 10 {mho/cm. preferably 0.5 mho/cm}

pH: 6 - 8
Dissolved O2: Minimum, preferably less than 100
ppb. Dissolved CO2: Minimum, permissible
conductivity. Chlorides: after a strongly acidic cat ion
exchanger.
Other anions: < 0.2 [ mho/cm].
Ammonia: Minimum, test with Nessler’s solution as a regent shall not cause a
change in color. Cu, dissolved.
Undissolved: Less than 20 ppb Fe, dissolved.
Undissolved: Less than 20 ppb.
Dissolved solids: The water shall not contain chemicals from treatment processes,
such as hydrazine, morpholine, levoxine, phosphate, etc.

62
 Primary water pumps
Kind of pump Centrifugal pump
Type CPK-CM 65-250 (S) M/s KSB make
Speed 2950 RPM
Capacity 70 m3/Hr
Discharge head 80 m
Pump motor ND225 M (M/s Crompton Greaves Ltd)
Rating 37KW
Voltage 415V, 3 Ph A C 50Hz
Frequency 50 Hz
Speed 2950 RPM
Type of enclosure TEFC
Nos. 2x100% capacity

Main filters
Kind of filter Strainer-type filter with magnet bars
Type 1.53.1 (M/s Boll & Kirch)
Volumetric flow rate 25 dm3/s max.
Degree of filtration 150 mm
Pressure drop across filter 0.1 bar with clean filter
1.2 bar with 100% fouling
Nos 2x100% capacity
Fine filter
Kind of filter 1 plug. 1 cartridge
Type 1.55.1 (M/s Boll & Kirch)
Volumetric flow rate 0.42 dm3/s max.
0.15 bar with clean filter, 1.2 bar with 100%
Pressure drop across filter fouling
Nos 1x100% capacity
Ion exchanger
Volume 83 lit
Resin Volume Lewatit
Resin Volume 56 litres (45 kg)
Nos 1x100% capacity

63
Specification for Ion Exchange Resins

General

The primary water must have a low conductivity since it comes into direct
contact with the high-voltage winding. To maintain a low conductivity the primary
water requires continuous treatment. This is achieved by continuously passing a
small primary water volume flow through a mixed bed ion exchanger arranged in
the bypass of the main cooling circuit. The ion exchange resins must be replaced at
certain intervals. The resins may be replaced while the generator is in operation,
since with the water treatment system out of service the conductivity will continue
to rise only very slowly.

2. Resin Specifications

The resins should contain no impurities or soluble substances having a

detrimental effect on the materials used in the primary water circuit and thus on the
availability of the generator. Our recommendation to use Lewatit ion exchange

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resins is based on many years of service experience and the close cooperation
between the resin supplier and many power plant operators as well as the high
quality standard of the resins. The initial charge of the mixed-bed ion exchanger
consists of the following types of resins.

 Lewatit S 100 KR/H/chloride-free

 Lewatit M 500 KR/OH/chloride-free

When replacing the resins, use either the above types or resins available from
other manufacturers which must comply with the specification below.

Specification for Alkalizer Unit

Despite the use of oxygen-poor water, corrosion of copper in the primary

water circuits of water-cooled windings cannot be completely avoided, and in
isolated cases the corrosion products can reduce the cross-sectional flow area of the
water distribution system.

The severity of the corrosion attack can be substantially reduced by

alkalizing the oxygen-poor water. In addition, the system becomes less susceptible
to disturbances resulting from air in-leakage. Operating the generator with alkaline
water at pH 8 to 9 will improve the reliability and availability of the turbine
generator. For operation of the alkalizer unit, dilute sodium hydroxide for
continuous injection into the primary water circuit and lime are required.

1) Sodium Hydroxide Solution

The sodium hydroxide solution should have a concentration of 10 to 20 g of

N a O H per dm3. Sodium hydroxide solution should be prepared from:

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Caustic Soda [NaOH] of P.A. quality, containing. Noah : > 98% Carbonates
[Na2CO3] : < 1% Water in conformity with the primary water specification

2) Lime

A lime filter to be provided in the N a O H tank vent serves to bind the carbon

dioxide (CO 2) contained in the inlet air in order to prevent the formation of carbonates in the

sodium hydroxide solution. The lime filter consists of equal parts of sodium hydroxide

(NaOH ) and calcium hydroxide (Ca (OH) 2). This mixture is commercially available and

known as soda lime.

Electrical Connection of Bars

The electrical connection between the top and bottom bars is by a bolted
contact surface. At their ends the strands are brazed into a connecting sleeve, the
strand rows being separated from each other by spaces. The contact surfaces of the
connecting sleeves for the top and bottom bars are pressed against each other.

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 Fig: Electrical Bar Connections and Water

The water connection at the stator bar is separate from the electrical
connection. As a result no electrical forces can act on the water connection. While the
solid strands of the stator bars terminate at the connecting sleeve, the hollow strands
are brazed into water boxes, with solid spacers inserted to compensate for the solid
strands. Each water box consists of two parts, i.e. the sleeve-shaped lower part
enclosing the hollow strands and the cover-type upper part.

The strand rows are separated from each other by spillers. Each water box is
provided with a pipe connection of non-magnetic stainless steel for connection of
the hose. The exciter-end water boxes serve for water admission and distribute the
cooling water uniformly to the hollow strands of the bar. The hot water is collected
on leaving the hollow strands in the turbine-end water boxes.

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 The cooling water is then discharged from the generator via the hoses and the
ring header. During manufacturing of t he stator bars, various checks are performed
to ensure water tightness and unobstructed water passages. The flow check ensures
that no reduction in the cross sectional area of the strand ducts has occurred, and
that all strands are passed by identical water flows. After brazing of the upper part
of the water box, all brazed joints are subjected to a helium leakage test followed by a
thermal shock treatment.

The tangential air clearance between the water boxes and bar connections
within a coil group and the axial clearance relative to the inner shield, which is at
ground potential, is so dimensioned that additional insulation is not required. For
the spaces between the individual phases insulating caps, which enclose both the
connecting sleeves and the water boxes, are connected to the stator bars.

Primary Water Cooler specifications

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Main Filter

The primary water system includes a strainer-type main filter with magnet
bars. The filter screen of the strainer has a mesh size of 75 mm (3 mils) and is
supported by a perforated sheet-metal cylinder. The magnet bars consist of a magnet
carrier and a number of permanent magnets.

The high-grade permanent magnets have an unlimited useful service life. The
magnet bars are arranged so that a strong magnetic field is set up between them.
The primary water must pass through this magnetic field so that all iron particles
come within the range of the magnetic bars, and are thus attracted and retained.

The magnet bar is protected by stainless steel sleeves. On contamination of

the strainer-type filter, which is indicated by an alarm initiated at excessive
differential pressure, the filter should be cleaned.

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 Seal Oil System
Hydrogen loss in Generator
 Hydrogen will escape from the gap of stator and rotor and will form an
explosive mixture.
 Cooling will be hampered as hydrogen escapes.
 Proper purity of Hydrogen is maintained for better efficiency.

Hence proper sealing is required in Generator to avoid escape of Hydrogen.

How Hydrogen Sealing is done?

 Shaft seal with oil under pressure are provided with radial seal rings. The seal
ring is guided into the seal ring carrier which is located in stator end shield.
 To ensure proper sealing oil is maintained at a higher level than gas pressure
so that hydrogen does not escape to atmosphere.
 Shaft seal is supplied with seal oil by a separate closed circuit system.

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Shaft seals

 The rotor shaft ends are brought out of the gas tight enclosure through double
flow shaft seals.
 The double flow shaft seal is characterized by its short axial length, its
independence from the respective from axial and radial position of the shaft,
and low hydrogen losses due to absorption by the seal oil.

 The seal oil is fed to the ring at pressure higher than the H 2 pressure.

 In addition to this air side seal oil at higher pressure is supplied to the
shaft seal for thrust loading of the seal.

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 CONCLUSION

Power is an important infrastructure in developing countries. Power

development in India received a big boost with the dawn of National Thermal
Power Corporation Limited.

Ramagundam Super Thermal Power Station is a plant with switching station

for southern grid, distributing 400 KV, generating 2600 MW, having mines, and Rail
transport facility.

This project report has given the basic idea of process for electrical power
production in thermal power plant. Flow path of water and steam in boiler and
steam in turbine. It is also provided typical values of important parameters and
major equipments used in thermal power production.

This project report has also given details like history of alternator development,
significance of generator cooling system, types of cooling systems and procedures to
follow improve performance of generators.

In future there is a scope of installing large capacity generators to have better

grid stability and the cooling of generators will play important role while designing
large capacity generators.

Now, it is time to handling the large size generators with higher efficiency and
better cooling methods to produce power efficiently and eco-friendly.

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References
1) www.ntpc.co.in
2) www.wikepedia.org
3) www.google.co.in
4) www.answers.com
5) Godavari Intranet http://191.254.4.10

Bibliography

 Schematic Diary of Stage 2.

 BHEL Generator O & M Manual.

***

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