CHAPTER -1

INTRODUCTION TO TURBO GENERATORS

1. INTRODUCTION
Electricity does not occur naturally in usable form and it cannot be stored usefully
in large quantities. Therefore it must be generated continuously to meet the demand at all
times. It also improves the economy of a country. A generator means an efficient &
convenient way to generate electrical power by conversion of mechanical energy to
electrical energy in a rotating device.

Turbo generator means a generator directly

coupled to a turbine which can be either steam or gas. These are used for power
production on large-scale basis.

1.1 PRINCIPLE
A generator works on the basic principle of Faradays Law of Electromagnetic
Induction. According to the law, When a conductor is mover in a stationary magnetic
field (or) when the magnetic fields is moved across the stationary conductor, an E.M.F is
induced in the conductor. When the conductor cuts the magnetic flux produced by the
magnetic field, current flows through the load when the circuit is closed.

ESSENTIAL PARTS OF A GENERATOR

The basic essential parts of a generator are

A magnetic field

A conductor (or) conductors which can move so as to cut the flux.

1.2 CLASSIFICATION OF GENERATORS

Generators can be broadly classified into two types as:
1)

DCGenerator

2)

A C G e ne r a t o r

DC GENERATORS

In DC Generators, the armature rotates and the field system is stationary.

AC GENERATORS

AC Generators are also known as Alternators. Here the field system rotates and
the armature is stationary.

CLASSIFICATION OF DC GENERATORS
DC Generators can be broadly classified into three types.
1. Shut Generators.
2. Series Generators.
3. Compound Generators.

CLASSIFICATION OF AC GENENRATORS
AC Generators can be broadly classified into two types.
1. Asynchronous generators.
2. Synchronous generators.

ASYCHRONOUS GENERATORS
Asynchronous generators are those in which the speed of rotor and flux are not in
synchronism. E.g.: Induction motor.

SYNCHRONOUS GENERATORS
Synchronous generators (or) alternators are those in which the speed of the rotor
and flux are in synchronism. The 3-phase synchronous generators are widely used
machines for power production on large scale basis. These when connected to turbines
are called turbo generators. Gas turbine generators and steam turbine generators are
widely used for power generation. Synchronous generators can be classified into various
types based on the medium used for generation.
They are:
1. Turbo- alternators:

Steam

Gas

2. Hydro Generators.
3. Engine Driven Generators.
Turbo generator mainly consists of 3 parts
1. Stator
2. Rotor
3. Excitation system.

1.3 STATOR
Armature windings are mounted on a stationary element called the stator. The
main parts of a stator are
1. Stator Frame.
2. Stator Core
3. Stator Winding.
3

STATOR FRAME
The stator frame is of horizontally split type and welded construction and supports
the laminated core and the winding. Ventilation holes are provided in the frame itself and
helps in cooling the machine.

STATOR CORE
The stator core is made up of stacked insulated silicon steel laminations. The core
is laminated to minimize loss due to eddy currents. Spaces are provided between the
laminations to allow the cooling air to pass through. The slots for housing the armature
conductors lie along the inner periphery of the core.

STATOR WINDING
The stator winding is a fractional pitch double layer lap winding. The bars are
located in slots which are uniformly distributed on the circumference of the stator core.

1.4 ROTOR
Field windings are mounted on a rotating element called rotor.
The main parts of the rotor are
1. Rotor Shaft.
2. Rotor Winding.
3. Retaining Rings.
4. Field Connections.
5. Bearings.

ROTOR SHAFT
Rotor shaft is a solid forging into which slots for insertion of field winding are
milled using the Heller machine.

The longitudinal slots are distributed over the

circumference so that solid poles are obtained. It is then sent for red gel painting.

ROTOR WINDING
Rotor windings are made up of copper strips. Each individual conductor is placed
over a template and passed under the ventilation punching machine. On both sides of the
conductor 900 bending is carried out. The conductors are then subjected for Annealing,
Hydraulic pressing on both the bends and checking with gauges carried out. On both the
ends of the conductor dovetailed punching is done. Air dry varnish is applied and relief
filing is done on both sides of the conductor. All the bars are assembled on a dummy
rotor and brazed to make one full coil. After red gel painting, the rotor slots are checked
for foreign matter presence and windings are assembled. Footings assembly is carried
out on both sides and diameter is checked. Input lead is assembled into the rotor shaft on
the exciter side. It is enclosed with H G L (Hardened Glass Lamination) insulation and
two D-leads are separated and surrounded with insulation and is checked for H.V. The
output studs are assembled onto the rotor for connections. Wedging is carried out using
high electrical conductivity material which act as damper winding Overhang braces are
assembled in between the conductors to protect from electrical short circuits. HV AC
and Impedance tests are conducted.

RETAINING RINGS
Assembly of retaining rings, the contact surface of which is sprayed with silver, is
carried out on both turbine and exciter side on the overhang part of the rotor body by
heating it to 2500C. Then the snap ring is released into the groove of the retaining ring.
Before assembling the retaining rings ensure the snap ring movement into the rotor

groove and lock it. After cooling the retaining rings, the rotor is subjected for HV and
impedance tests.

FIELD CONNECTIONS
The two output leads which are brought out towards the exciter side are connected
tote excitation system and the field current is supplied to the rotor.

BEARINGS

The rotor is supported in two sleeve bearings. The temperature of the bearings is
maintained with two RTDs (Resistance Temperature Detector) embedded in the lower
bearing sleeve so that the ensuring point is located directly below the Babbitt. All
bearings have provisions to monitor the shaft vibrations. The oil supply to the bearing is
obtained from the turbine oil system.

1.5 COOLING SYSTEM

There are various losses occurring in a generator due to which heat is generated.
Hence cooling system is a basic requirement for any generator. The insulation used and
cooling system employed are inter-related. The various losses in a generator are:
1. Iron Losses

Hysteresis Losses

Eddy Current Losses

2. Copper Losses
3. Mechanical Losses

Friction losses

Winding losses
These losses dissipate as heat and raise the temperature of the generator which effects the
insulation. Therefore it should be cooled to avoid excessive temperature rise. So the

class of insulation used depends mainly on the cooling system installed. There are
various methods of cooling.
They are:
1). Air cooling

- 60MW

2). Hydrogen Cooling

- 100MW

3). Water Cooling

- 500MW

4). H2 & Water Cooling

- 1000MW

Hydrogen cooling has the following advantages:

1. H2 has seven times more heat dissipation capacity.
2. Higher specific heat.
3. Since H2 is 1/14 thof air weight, it has higher compressibility.
4. It does not support combustion.
Hydrogen cooling has the following disadvantages:
1. It is an explosive when mixed with oxygen
2. Cost of running is higher

CHAPTER -2
MANUFACTURING OF STATOR
MANUFACTURING OF STATOR
The different stages involved in the manufacturing of stator are:
1. Lamination Preparation.
2. Stator Core Assembly.
3. Stator Winding.
4. Stator Assembly.

2.1 LAMINATION PREPARATION

The building up of the core using laminations plays a vital role to minimize the
magnetic losses which are of two types,

Hysteresis Losses occur due to residual magnetism in the material.

Eddy Current Losses occur due to the emf produced in the core.
In order to minimize the Hysteresis losses, silicon alloyed steel sheets are used for
building up of the core. These sheets are 4% Silicon Alloyed COLD ROLLED NON
GRAIN ORIENTED (CRNGO). The sheets have the following composition,
Steel

: 95.8%

Sillicon

: 4%

Impurities

: 0.2%

In order to minimize the Eddy Current losses, the core is built up of 0.5mm thick
laminations which are insulated from each other using class B type oil varnish. The
preparation of the lamination involves the following process.

1. RECEPTION OF SILICON SHEETS

The silicon roll sheets are received in the form of bundles.
8

2. EXAMINATION OF SILICON SHEETS

The received silicon sheets are examined for the specified electrical, magnetic and
mechanical properties.

3. BLANKING

It is the process where the required shape of the lamination is obtained by passing
on the rollers and cutting into required size. The specified dimension sheet obtained from
cutting process is called Blanking and the remaining waste material is called
Perforation.

4. NOTCHING
This is the process where slots are punched into the blanked sheet. There are two
types of notching.

INDIVIDUAL NOTCHING: Each operation is carried out independently & the

probability of error is high.

COMPOUND NOTCHING: Processing the laminations at single stroke & the

probability of error is less.

5. DUBURRING
Each lamination is processed for deburring operation i.e. removing the bur level
which prevents from short circuit. The acceptable limit of the bur is 5 microns

6. VARNISHING
This is done to insulate the lamination using ALKYD PHENOL VARNISH.
The laminated sheets are passed through a conveyor which has an arrangement to
9

Sprinkle a coat of varnish. The coating thickness should be 7 to 10 microns/side. The

Varnish used should be of correct viscosity which is measured using a din-four-cup.
After varnishing, laminations are passed through furnace where temperature is
Maintained at 3000C 4000C.

TESTS PERFORMED AFTER VARNISHING

Checking hardness, the hardness of the varnish coating is checked using a 7H pencil.

Bonding adhesive test: Pour Xylol on the lamination and wait for one minute. The
varnish coating should not dissolve the xylol.

IR Value test: This test is performed using Megger. When twenty laminations are
stacked under a pressure of 26kg/cm2 the IR value should be greater than 1 Mohm.

Uniformity test: It is measured using a mini tester after giving two coats of varnish.

2.2 STATOR CORE ASSEMBLY

The purpose of stator core is:
a) To support the winding.
b) To carry the flux. The assembly of the stator core involves the following processes:

1. ASSEMBLY OF TRIAL PACKETS

A clamping plates is placed on the assembly bed which is already aligned
horizontally with spirit level. Laminations are assembled on this clamping plate one after
the other to form 3600 or inside diameter and up to a width of 50 to 100 mm. All the slots
are checked with inspection drift. The inside diameter of the core is checked with inside
micrometer. After fulfilling all the above requirements, the trial packed assembly is
dismantled.

10

2. ASSEMBLY OF NORMAL PACKETS

The stepped packets are assembled on the clamping plate by inserting assembly
drifts into the slots and mandrels in all the respective holes. The stepped arrangement of
the laminations at the core ends provides an efficient support to the tooth portion and
reduction of eddy current losses and heating. It is carried out by laying individual
laminations to obtain the required width of the packet. Over it one layer of HGL sheet
and one layer of ventilation lamination are assembled. Once again the normal packet
assembly is carried out up to required width. After completion of two packets, the inside
diameter of the core is checked and also inspection drifts is passed in all slots, The above
process is repeated up to 800mm and first pressing is done. Similarly the above process
is again repeated up to 800mm and second pressing is done.

3. ASSEMBLY OF GUIDE BARS

All the guide bars assembly is carried out by placing required number of holding
half rings. One guide bar is earthed called Earth Bar. Required hydraulic pressure is
given to the rings until the guide bars are seated into the dovetailed slots. All the guide
bars & holding rings are welded in a systematic manner. Winding brackets are welded
and checked for 900 on both sides.

4. TESTS PERFORMED ON THE CORE

Dipenetrant test: To check for any cracks during welding.
Core Flux test

: To detect the presence of hot spots.

5. PROVISION OF CORE RTD AND TOOTH RTD

RTDS are placed to detect temperature in between the winding and on the core.

11

6. FIRE DETECTORS
On the overhang portion, fire detectors are placed to detect occurrence of fire due
to short circuit.

2.3 STATOR WINDING

The winding used in the stator is of Roebel type. The manufacturing of the
winding involves the following processes.

1. RECEPTION OF THE METERIAL

The material used for the winding consists of 99% copper and1% silver which has
class-F type of insulation.

2. CHECKING OF THE RAW MATERIAL

The raw material is cross checked for electrical mechanical an chemical
properties.

3. CUTTING
The copper strips are cut according to the given design.

4. TRANSPOSITION
The copper strips are 1800 transposed by applying a pressure of 150kg/cm2.
Transposition is done to equalize the induced emf in all the strands, to minimize I2R
losses and skin effect. Also the heat distribution is equal.

12

5. BUNDLING
The 1800 transposed coils are placed one above the other to form a bundle. Hlaf
insulation is placed between the two transposed coils and the bundle is tied with cotton
tape.

6. PUTTY WORK
The uneven surface formed during transposition are filled with nomex sheets to
prevent inter-half and inter-strip short Mica fleece is placed on the width of the bar and
PTFE (Poly Tetra Fluoro Ethylene) is wrapped on the straight portion.

7. STRAIGHT PART CONSOLIDATION

The bar is subjected to a pressure of 150kg/cm2 horizontally and vertically and
temperature of 1600C for 2-3 hours. The bar is consolidated such that there are no air
gaps.

8. DIMENSION CHECK:
The dimension i.e. both width and height are checked using a guage.

9. TESTING
The tests performed on the bar are interstrip and inter half. These tests are
performed using a lamp which is connected between a phase and neutral. The two
terminals are connected for:
Inter strip -> between strips.
Inter half -> between two coils of a bundle.

If the lamp glows, it indicates that a short circuit has occurred.

13

10. BENDING
Bending process is carried out on the bending fixture. After bending, the bar is in
the shape of half diamond and is hence called as half diamond coil.

11. OVERHANG CONSOLIDATION

Manufacturing &Insulation System By VPI Process For Air Cooled Turbo
Generators Nomex pieces are inserted by applying rotopax and hardner from first bend to
third bend between the two coils a bundle. Both the overhang portion and consolidated
using clamps and heating to a temperature of 600C to 700C for a duration of 30 minturs.

12.COPPER FOIL SOLDERING

A copper foil is soldered on the width of the bar to prevent internal corona discharges.

13. FINISHING, TESTING & DIMENSIONAL CHECK

Finishing, testing and dimensional check is carried out before taking the bar for
final taping.

14. FINAL TAPING

It is carried out with machine or manually to obtain the designed insulation wall
thickness around the periphery of the stator bar in the straight portion, overhang portion
and third bend portion

Resin poor tape is wrapped throughout the bar with 1*1/2 overlap.

Resin poor tape is wrapped on the overhang portion of the bar with 6*1/2 over lap.

Copper foil is placed along the width of the bar and ICP (internal corona protection tape
is wound.

14

Resin poor tape is again wrapped through out the bar with 8*1/2 overlap.

OCP (outer corona protection) tape is wound on the straight part along with split mica
tape on the width of the bar simultaneously so that mica is not over lapped.

15. TESTING
Inter-half testing is carried out before sending the bar to stator assembly.

2.4 STATOR ASSEMBLY

1. RECEPTION OF STATOR BARS
All the bars are checked physically for dimensions and quality. Each bar is
pressed at a pressure of 60kg/cm2 in the pressing fixture for duration of 30-45 minutes to
obtain the desired width such that the bar is easily placed into the slot. during pressing
the bar is tested for inter half shorts.

2. RECEPTION OF STATOR CORE

The stator core received from the core assembly is checked for foreign matter.
The insulation drift is passed in all the slots to check for the laminations projections .It is
rotated continuously so that all the foreign matter comes out.

3. WINDING HOLDER ASSEMBLY

The winding holder s are assembled onto the winding brackets on the turbine side
as well as the exciter side.

4. HGL RINGS CENTERED TO THE CORE

15

HGL rings are assembled and centered to the core on both the turbine and exciter
sides. All the slots and the RTD (resistance temperature detector) slots are identified with
numbers.

5. LAYING OF THE BOTTOM BAR

All the bars are inserted into the respective slots and checked for pitch matching.
Before laying the bottom bars, a conductive fleece is laid into the slot to discharge the
charges. A 5 mm glass mat is placed underneath the winding holders. Two bars are laid
in the consecutive slots and tied to the winding holders with Neoprene glass sleeve by
inserting spaces in between them. All the bars are laid in the slots by following the above
procedure. The seating of the bottom bar is checked with a guage and weding is carried
out for the bottom bars. All the bars are subjected to H.V.DC test i.e. 16.8KV or
17.2KV.

6. LAYING OF THE TOP BAR

Before laying the top bars, stiffners are adapted on the winding holders on which
5mm glass mat is laid and interlayer inserts are inserted on the both turbine and exciter
side. All the bars are laid into the respective slots and checked for pitch matching.
Subject the top bars for H.V DC i.e. 16.8KV or 17.2KV. Wedging is carried out in all the
slots. Both the bottom and top bars are subjected for H.V test.

7. EYES JOINING ON BOTH THE SIDES

Manufacturing & insulation System by VPI Process For Air cooled Turbo
GeneratorsStrip to strip bracing of the conductors in the overhang portion is done using a
silver foil which contains 14% silver and remaining is tin.

16

8. ASSEMBLY OF CONNECTING RINGS

Inter half test is carried out for the three phases. Assemble all the connectors and
join or brace all the twelve eyes to the connectors. Terminate the three phases and three
nautrals.

9. INSULATION OF EYES
Insert nomex sheets between the two halves of the eye insulate each eye with
3X1/2 layers of semica folium glass plate. Ultimately wrap hyper seal tape.

ROTOR WINDING

17

STATOR WINDING

18

ROTOR
Solid rotors are manufactured from forged alloy steel with suitable alloying
elements to achieve very high mechanical and superior magnetic properties.
Rectangular or trapezoidal rotor slots are accurately machined to close tolerances
on slot milling machine. For indirectly cooled generator rotors, ventilation slots are
machined in the teeth. For directly cooled rotors, sub slots are provided for cooling
Generator rotors of 1500 RPM are of round laminated construction.

Punched and

varnished laminations of high tensile steel are mounted over machined shaft and are
firmly clamped by end clamping plates.

2.1 ROTOR SHAFT

Rotor shaft is a single piece solid forming manufactured from a vacuum casting.
It is forged from a vacuum cast steel ingot. Slots for insertion or the field winding are
milled into rotor body. The longitudinal slots are distributed over the circumference such
that two solid poles are obtained.
To ensure that only a high quality product is obtained, strength tests, material
analysis and ultrasonic tests are performed during the manufacture of rotor. The high
mechanical stresses resulting from the centrifugal forces and short circuit torques call for
a high quality heat treated steel. Comprehensive tests ensure adherence to the specified
mechanical and magnetic properties as well as homogenous forging. After completion,
the rotor is balanced in various planes at different speeds and then subjected to an over
speed test at 120% of the rated speed for two minutes.
The rotor consists of electrically active portion and two shaft ends.
Approximately 60% of rotor body circumference has longitudinal slots which hold the
field winding. Slot pitch is selected so that the two solid poles are displaced by 180
degrees. The rotor wedges act as damper winding within the range of winding slots. The
rotor teeth at the ends of rotor body are provided with axial and radial holes enabling the
cooling air to be discharged into the air gap after intensive cooling of end windings.

19

2.2

ROTOR WINDINGS
The rotor windings consist of several coils inserted into the slots and series

connected such that two coil groups form one pole. Each coil consists of several series
connected turns, each of which consists of two half turns connected by brazing in the end
section. The rotor bearing is made of silver bearing copper ensuring an increased thermal
stability.
The individual turns of coils are insulated against each other by interlayer
insulation. L-shaped strips of laminated epoxy glass fibre fabric with nomex filter are
used for slot insulation.
The slot wedges are made of high electrical conductivity material and thus act as
damper windings. At their ends the slot wedges are short circuited through the rotor
body.

CONSTRUCTION
The field winding consists of several series connected coils inserted into the
longitudinal slots of rotor body. The coils are wound so that two poles are obtained. The
solid conductors have a rectangular cross section and are provided with axial slots for
radial discharge or cooling air. All conductors have identical copper and cooling duct
cross section. The individual bars are bent to obtain half turns. After insertion into the
rotor slots, these turns are brazed to obtain full turns. The series connected turns of one
slot constitute one coil. The individual coils of rotor are connected in a way that one
north and one south pole is obtained.

CONDUCTOR MATERIAL
The conductors are made of copper with a silver content of approximately 0.1%.
As compared to electrolytic copper, silver alloyed copper features high strength
properties at high temperatures so that coil deformations due to thermal stresses are
eliminated.
20

INSULATION
The insulation between the individual turns is made of layer of glass fiber
laminate. The coils are insulated from the rotor body with L-shaped strips of glass fiber
laminate with nomex interlines.
To obtain the required leakage paths between the coil and the rotor body thick top
strips of glass fiber laminate are inserted below top wedges. The top strips are provided
with axial slots of the same cross section and spacing as used on the rotor winding.

ROTOR SLOT WEDGES

To protect the winding against the effects of centrifugal forces. The winding is
secured in the slots with wedges. The slot wedges are made of copper alloy featuring
high strength and good electrical conductivity. They are also used as damper winding
bars. The slot wedges extend beyond the shrink seats of retaining rings act on the damper
winding in the event of abnormal operations. The rings act as short circuit rings in the
damper windings.

END WINDING BRACING

The spaces between the individual coils in the end winding are filled with
insulated members that prevent coil movement. Two insulation plates held by HGL high
glass laminate plates separate the different cooling zones in the overhangs on either sides.

2.3

ROTOR RETAINING RINGS

The centrifugal forces of the rotor end winding are contained by single piece rotor

retaining rings. 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 overhang position. The retaining ring is secured in the axial position
by snap rings.
21

The rotor retaining rings withstand the centrifugal forces due to end windings.
One end of each ring is shrunk fitted on the rotor body while the other end overhangs the
end windings without contact on the rotor shaft. This ensures and unobstructed shaft
deflection at the end winding.
The shrunk on hub on the end of the retaining ring serves to reinforce the
retaining ring and secures the end winding in the axial direction at the same time.
A snap ring is provided against axial displacement of retaining ring. The shrunk
seat of the retaining ring is silver plated, ensuring a low contact resistance for induced
currents. To reduce the stray losses and have high strength, the rings are made of non
magnetic, cold worked materials.

2.4

ROTOR FANS
The cooling air in generator is circulated by two axial flow fans located on the

rotor shaft one at each end. To augment the cooling of the rotor winding, the pressure
established by the fan works in conjunction with the air expelled from the discharge parts
along the rotor.
The blades of the fan have threaded roots for being screwed into the rotor shaft.
The blades are drop forged from an aluminium alloy. Threaded root fastenings permit
angle to be changed. Each blade is secured as its root with a threaded pin.
BEARINGS
The turbo generators are provided with pressure lubricated self-aligning elliptical
type bearings to ensure higher mechanical stability and reduced vibration in operation.
The bearings are provided with suitable temperature element devices to monitor bearing
metal temperature n operation.
The temperature of each bearing is monitored with two RTDs (Resistance Thermo
Detectors) embedded in the lower bearing sleeve such that the measuring point is located
directly below the babitt. These RTDs are monitored a temperature scanner in the
control panel and annunciated if the temperature exceeds the prescribed limits. All
bearings have provisions for fitting vibration pickups to monitor shaft vibrations.

22

To prevent damage to the journals due to shaft currents, bearings and oil piping
on either side of the non drive end bearings are insulated from the foundation frame.
For facilitating and monitoring the healthiness of bearing insulation, split insulation is
provided.

VENTILATION AND COOLING

Turbo generators are designed with the following ventilation systems:

Closed circuit air cooling with water or air coolers mounted in the pit.

Closed circuit hydrogen cooling with water or hydrogen mounted axially on the stator
frame.The fan design usually consists of two axial fans on either made of cast aluminium
with integral fan blades or forged and machined aluminium alloy blades screwed to the
rotor. In case of 1500 RPM generators, fabricated radial fans are provided.

TESTING OF TURBO GENERATOR

To ensure that all functional requirements are fulfilled, and to estimate the
performance of generator, the TURBO GENERATORS are required to undergo some
tests. For testing, the TURBO GENERATOR was mechanically coupled to a drive
motor-motor generator set with gearbox. The rotor was excited by thyristor converter
system located in an independent test room and the operation was controlled from the test
gallery.
The following first two tests will be conducted on the stator and rotor before
assembling and the third and final routines tests will be conducted after after assembling
the turbo generator.
a) Tests conducted on rotor
b) Tests conducted on stator
c) Routine tests on turbo generators

23

Rotor of Brushless
Exciter

Armatu
re

Perma
nent
Magne
ts

Diode
Wheel

E/f
Monito
ring
Slip
Rings

Rotatin
g
Diodes
&
Fuses
24

Brushless Exciter Complete

Assembly

Stator

Cooling
Fan

Armatur
e
25

Diode
Wheel

TESTING OF TURBO GENERAROR ROTOR WINDING

Details of Process tests to be performed at various stages
HIGH VOLTAGE TEST
1. After mounting the excitation lead and slip rings and before actually commencing the
winding , the slip rings are to be tested.
First, measure the insulation resistance with 1000v Megger, if the insulation condition is
found satisfactory, then perform High Voltage test for one minute, the test of which is to
be determined according to the following equation.
U2 =Ut + 1 K V
Where U2 is test voltage
Ut is 10* rated rotor voltage
However the resulting test voltage U2 should be neither lower than 2.5 K V nor
above 4.5 KV.
After the high voltage test, measure the insulating condition again with 1000 V
Megger.
2. The next test is to be carried out after placing all the coils in the respective rotor slots
and before clamping the pressing equipment. Measure the insulating condition with a
1000V megger. It must not be lower than I MO for each K V of the tested voltage. Then
measure the ohmic resistance of the winding.
3. After tightening the winding with the pressing and tightening equipment and before
actually baking the winding, measure the ohmic resistance of the winding. Then check
polarity of the winding.
While clamping care should be taken to see that the pressing rings and other
equipment are insulated from the winding and rotor body, by inserting insulation in every
slot under the shims of the equipment.
4. After baking and forming of the winding and removing of the clamping equipment and
after the rotor cools down to ambient temperature, measure the insulation resistance with
1000V Megger..
If the insulation condition is satisfactory, perform High Voltage test for one
minute with a value of 1.15 Ut.
26

When Ut is 10 times the rated rotor voltage.

After performing the High Voltage test, measure again the insulation condition.
5. After driving the central wedges only in position, measure the insulation resistance and
if found satisfactory, perform High Voltage test with a value of 1.10 Ut for 10 sec, i.e.,
just reaching the value and then bringing down to zero.
After driving all the wedges in position, measure the insulation resistance and if
found satisfactory, perform High Voltage test with a value of 1.10 Ut for one minute.
6. After putting all the bracings, mounting of the end retaining ring and just before
Dispatch of the rotor for further machining.
7. After machining of the rotor, and before is dispatch to the centrifugal tunnel, measure
the insulation resistance.
8. After setting the rotor in the centrifugal tunnel, check the insulation resistance and the
ohmic resistance, while the rotor is at rest. Check again the insulation condition at
3000rpm.
Measure again the insulation resistance after the rotor is balanced and just before
its dispatch to the winding shop.
9. Finally, just before the dispatch of the finished rotor measure the insulation resistance
and perform High Voltage test with a value of 1.0 Ut for one minute.

MEASUREMENT OF D.C.RESISTANCE

The D.C. resistance value of rotor winding is measured by using a Micro

Ohmmeter. First connect the micro ohmmeter to 230V AC supply. And measure the
resistance and the temperature using RTD. This resistance at T temperature has to be
converted to resistance at 20 Degrees C by using the formula:
R20 = Rt * (235+20)/(235+T) milli ohms.
Where R20 = Resistance at 20 Degrees C in mO
T = temp in degree Celsius
Rt = measured resistance of winding in mO
A deviation of 10% from design values is acceptable.

27

MEASUREMENT OF IMPEDANCE

By applying 50-200 V in steps of 50V, Impedance value is measured at standstill

and at the rated speed.
Impedance is measured by using the formula :
Z = V/I
Where Z impedance in ohms;
V = voltage in volts;
I = current in amps;
In the measurement of Impedance there will be a graph plotted between voltage
v/s current. In this, there is no perfect value for the impedance but the only condition is
that the impedance should increase with increase in voltage.

TESTING OF TURBO GENERATOR STATOR BARS

For resin rich systems, stator bars will be tested in the following order

1) After bars manufacturing bars are tested at four times the rated voltage.
Ut = 4* Urated
2) Individual bars will be tested for tan d d is the angle between actual current and line
current. When the insulation is perfect and dielectric strength is optimal d is zero. But
due to the presence of impurities there will be a phase angle difference between the two
currents.
This tan d measurement is known as loss angle measurement or dielectric loss
measurement. Tan d values should be within 2%.
3) Outer corona protection resistance is measured and this value should be within the range
of 75-300 0/Sq. cm
4) Inter strip and Inter half shorts are checked.

Inter strip means between the

conductor strips and inter half means between the halves. This shorts are checked by a
series bulb test.

28

Manufacturing of Turbo - Generators

EXCITERS

BRUSHLESS EXCITER
Suitable for mounting on synchronous generator.

CONSTRUCTION
The exciter is brush-less and takes the form of a stationary field generator. Its
rotor is mounted on the overhang of main machine shaft end. The stator may be fixed
either to be base frame of the main machine or to a separate steel or concrete foundation.
A permanent magnet three phase pilot exciter driven directly by the common shafting or
a static auxiliary excitation unit is used for exciting the field of the stationery field
generator via a voltage regulator.

The auxiliary excitation equipment is described

elsewhere. The three phase current flowing in the rotor winding is rectified by Silicon
diodes in the rotating rectifier and fed into the field winding of main machine via the
excitation leads which pass through the hallow shaft of the main machine.

ROTOR
The rotor is fitted on the shaft extension of the main machine and locked to it in
the circumferential direction by parallel keys which are capable of accepting shock loads
caused by short circuit in the main machine without being over stressed.
The rotor hub is of welded construction and called the laminated core which is
compressed axially by means of a clamping ring welded to the hub. Specially shaped
supporting elements for the rotating rectifier modules are welded between the arms of the
rotor spider within the ring formed by laminated core.

29

ROTOR WINDING
The 3-phase rotor winding inserted in the slots of the laminated core is connected
in star. It is a two layer winding to insulation of class F. The end leads of the individual
windings are on the A end and connected to the u,v,w and neutral bus rings arranged at
the same end. Both winding overhangs are bound with heat setting glass fiber tapes to
afford protection against centrifugal forces. The rotor winding is impregnated with
epoxy resin.

RECTIFIER
The rectifier accommodated inside the rotor core and rotor winding comprises six
diode assemblies and the protection circuit. The diode assemblies each consist of a light
metal heat sink with integrally formed cooling fans containing one disc type diode
secured by means of a clamping plate. As the heat sinks are electrically live, they are
insulated from the rotor hub to which they are fixed. A contact face provided on the
inside of each heat sink is connected by meanks of links to the appropriate bus ring on the
3-phase side. The connections to the dc bus rings are established by longitudinally
arranged bus connector, which is connected to the contact bolts protruding from the
clamping plates.
Diode assemblies situated on opposite sides of the rotor spider have opposite
polarities. The sign of polarity, which appears on the front face of the heat sink, should
be observed. The dc bus rings carry the protective varistors are screwed to the B end of
the rotor spider by means of insulating mounts. The two bus rings, each have a terminal
lug for the copper bars which are connected to the excitation cable of the main machine.
The excitation cables are led through the insulated hollow shaft of the main
machine and are provided with special cable lugs at the shaft openings.

VARISTOR
To protect the rectifier bridge against over voltages occurring during starting or
during fault conditions, a non linear resistor is provided.
30

This protective varistor

consists of 12 varistor discs in parallel, connected between the positive and negative bus
rings.
The varistor discs are clamped between the bus rings by means of insulated
screws. Electrical contact between the varistor discs and the bus rings is ensured by discs
of annealed copper inserted between them.

MAIN EXCITER
The 3 phase pilot exciter is a 6 pole revolving armature unit. Arranged in the
frame are the poles with the field and damper windings. The field winding is arranged on
the laminated magnetic poles. Each coil is made from individually insulated tube. To
reduce eddy current in the coil, copper strips in each coil is transposed. At the pole shoe,
hair is provided which are connected to form a damper winding. Between the 2 poles of
quadrature axis, a coil is fixed for inductive measurement of field current.

The rotor consists of stacked silicon steel laminations forming the rotor core. The
3 phase winding is inserted in the slots of laminated rotor. The winding conductors are
transposed with in the core length and the end turns of rotor winding are secured with
steel bands.
The stator slots form indentations in the air gap boundary. Therefore as the rotor
flux moves across the stator teeth the change in performance due to the slot opening
introduces median frequency pulsations. These pulsations induce harmonic voltages in
the surface of the stator teeth. But due to the laminated construction, the resultant leaves
are kept to minimum. The winding ends are connected to a burring system to which the 3
phase leads loading to the rectifier wheel are also connected. A journal bearing is
arranged between main the pilot exciters and has forced oil lubrication from the turbine
oil supply; rotor windings and core are air-cooled.

ROTATING RECTIFIER WHEEL

As power from the main exciter is fed to RR wheel it is converted to dc. The
main components of the rectifier wheel are the silicon diodes, which are arranged inside
31

the retaining ring in a 3-phase bridge circuit. The internal arrangement of the diode is
shown in fig. The arrangement of the diode is such that the contact pressure produced by
plate spring assembly is increased by the centrifugal force during rotation. The rotating
rectifier includes 20% standby capacity ensuring continued and restricted operation in the
unlikely event of the diode failure. Anode based diodes are used in positive arms and
cathode based diodes in negative arm of the bridge. Additional components contained in
rectifier wheel are heat sinks, RC networks, fuses, Each diode is mounted in each light
metal heat sink and thus connected in parallel associated with each diode with HRC fuse,
which serves to switch off the diode if it fails.
Rotating rectifier wheel is provided with 6 RC networks each consisting of one
capacitor and one damping resistor, which are connected, in single resin encapsulated
unit.
When high voltage surges occur, the capacitor gets charged until normal
conditions occur When a low voltage surge occurs, the charge through the capacitor is
dissipated through the damping resistor.
Three-phase alternating current is obtained via copper conductors arranged on the
shaft circumference between rectifier wheel and 3 phase main exciter. One 3 phase
conductor originating as a abus ring system of the main exciter is provided for each
diode.
The dc current from the rectifier wheels is fed to the DC leads arranged in the central
bore of the shaft via radial bolts.

PILOT EXCITER
Some of different types of pilot exciters are salient pole, inductor type, and
homopolar and heteropolar designs. Salient pole PMG is a 3-phase medium frequency
machine providing a constant voltage supply to the thyristor converter and AVR circuits.
PMG poles are manufactured from high-energy material such as Alcomax. The
permanent magnet pieces are bolted to a steel hub and held in place in place by pole shoe.
The bolts are made from non-magnetic steel to prevent formation of magnetic shunt. To
improve the waveform of the output voltage and reduce electrical noise, the pole shoes
32

are skewed one pole pitch over the stator length, Stator core is constructed from a stack
of low loss sheet steel laminations assembled within the fabricated steel frame. Radial
and axial cooling ducts are provided at intervals along the core length to allow cooling of
core and windings. The stator windings is a two layered, each conductor consisting of a
number of small diameter copper wires insulated with polyster enamel. The coils are
connected to give rated 3 phase voltage output and insulated with class F epoxy glass
material.
A steel frame is fitted over PMG stator provides mechanical protections and
reduces medium frequency noise emitted from the PMG to an acceptable level. Cooling
of PMG is achieved by drawing air through mesh-convered apertures in the frame.

AUTOMATIC VOLTAGE REGULATORS

The AVR is solid-state thyristor controlled equipment with very fat response. It
has two channels. Auto channel for voltage regulation and manual channel for feld
current regulation. Each channel has its own firing circuit and thyristor converter for
reliability.
Normally automatic regulation system is operative, including the startup and shut
down of the machine.

The set point adjuster of the excitation current controller

automatically follows up, so that change over to excitation current control is possible at
any time.

Under certain emergency and fault conditions, change over is initiated

automatically.
The two self-ventilated thyristor sets for voltage control (AUTO) and excitation
current control (MANUAL)

are designed to meet the normal safety requirements

regarding the current and voltage. In case of higher capacity thyristor bridge a separate
fuse protects each thyristor. The individual thyristor fuses of both AUTO and MANUAL
control systems are being monitored using miniature circuit breakers.
The voltage generated by the generator has to be maintained constant. This
constant voltage, taken as reference voltage, is fed to the error detector. The terminal
voltage of the generator is also fed to the error detector. Error signal is amplified in the
error amplifier. The output of the amplifier is fed to the gate pulse generator where the
33

pulsed are generated. These gate pulses are given to the gate terminals of the thyristors in
the bridge circult of either AUTO channel or MANUAL channel, thus triggering the
thyristors at required regular intervals.
The three-phase output of the permanent magnet generator is fed to the thyristor
bridge. The rectified signal from the thyristor bridge is fed to the main exciter field, so
that the pole are excited.

BL EXCITER

Machined34Rotor

STATOR CORE ASSMBLY

PMG

35

END SHIELD ASSEMBLY BEARING

FUSE

36

BEARING SHELL ASSEMBLY

37

38

AIR FLOW DIAGRAM OF GENERATOR

ARMATURE CORE ASSEMBLY

39

CHAPTER 3
INSULATING MATERIALS
3.0 INSULATING MATERIALS
Electrical insulating materials are defined as those which offer high resistance to
the flow of current. In the electrical machines and transformers, the insulating materials
applied to the conductors are required to be flexible and have high dielectric strength and
ability to withstand unlimited cycles of heating and cooling.

3.1 CHARACTERSTICS OF A GOOD INSULATING MATERIAL

Large insulation resistance.

High dielectric strength.

Uniform viscosity.

Should be uniform throughout least thermal expansion.

When exposed to arcing they should be non ignitable.

Resistant to oils, liquids, as flames, acids and alkalies.

No deteriorating effect on the material in contact with it.

Low dissipation factor.

High mechanical strength

High thermal conductivity.

3.2 CLASSIFICATION OF INSULATING MATERIALS

The insulating materials can be classified according to:
1. Substances and materials
2. Temperature.

40

3.3 PROPERTIES OF INSULATING MATERIALS

I. Electrical Properties.
II. Thermal Properties.
III. Chemical Properties.
IV. Mechanical Properties.

ELECTRICAL PROPERTIES
INSULATION RESISTANCE

It is defined as the resistance between two conductors usually separated by

materials i.e., one through the body and other over the surface of the body.

DIELECTRIC STRENGTH
The voltage across the insulating materials is increased slowly, the way in which
the leakage current increase depends upon the nature and condition of material.

POWER FACTOR
Power factor is a measure of the power losses in the insulation. It Should be low.
It increases with the rise in temperature of the insulation. A rapid increase indicates
danger.

DIELECTRIC CONSTANT
The property is defined as the ration of the electric flux density in the material to that
produced in free space by the same electric force.

41

DIELECTRIC LOSS:
The dielectric losses occur in all solid and lidquid dielectrics due to:
a. Conduction Current
b. Hysteresis.

THERMAL PROPERTIES

Specific heat thermal conductivity.

Thermal plasticity.

Ignitability.

Softening point.

Heat Ageing

CHEMICAL PROPERTIES

Resistant to external chemical effects.

Restistant to chemicals in soils

Effect of water.

MECHANICAL PROPERTIES

Density.

Viscosity.

Moisture absorption.

Hardness of surface.

Surface tension.

Uniformity.

42

EFFECT OF MOISTURE ON INSULATION

Thermal property

Chemical property

Electrical property

Physical property

Mechanical property

FACTORS AFFECTING INSULATION RESISTANCE

The factors which affect the insulation resistance(i.e., resistance between two
conductors) are:

It falls with every increase in temperature.

The sensitivity of the insulator is considerable in presence of moisture.

It decreases with increase in applied voltage

43

CHAPTER-4
INTRODUCTION TO INSULATION SYSTEM
4.0 INTRODUCTION TO INSULATION SYSTEM
In Electrical Machines insulation is the basic

requirement to sustain high

voltates.Insulation is the heart of the electrical machines and has enormous resistance to
conductivity i.e., the forbidden gap (or Fermi level) between the valence and the
conduction bands is very large.

4.1 PROPERTIES OF A GOOD INSULATION MATERIAL

1. Non-conductive to electricity & good conductor of heat.
2. Provides isolation between live wires or live wire & earth.
3. Should withstand the designed mechanical stress.
4. Good thermal and chemical resistivity.

METHODS FOR INSULATION

There are two methods of insulation.

They are:
Thermoplastic
Thermosetting.

4.2 THERMOPLASTIC
Thermoplastic process in that where the resin softens o heating and hardens on
cooling.

44

THERMOSETTING

Thermosetting process is that where the resin once hardened cannot be softened
even on heating. Thermosetting is again divided into two types.
They are
1. Resin Rich System.
2. Resin Poor System

RESIN RICH SYSTEM

CONTENTS
Resin content is 40%
Binder content.
Glass cloth.
Mica content
Volatiles.

RESIN POOR SYSTEM

CONTENTS

Resin contnt is 8%

Zine Napthenate

Glass cloth

Fine Mica content.

Volatiles.

45

4.3EPOXY RESINS
These resins are product of alkaline condensed of epichlorohydrin and polyhydric
compounds.

Epoxy resins are polyethers derived from epichlorohydrin and

bisphenolmonomers through condensation polymerization process

In epoxy resins, cross linking is produced by cure reaction. The liquid polymer
has reactive functional group like oil etc. Otherwise vacuum as pre polymer. The
prepolymer low inductor weights such as polyamines, polyamides, polyamides,
polysulphides, phenol, ureaformaldehyde, acids anhydrides etc, to produce the three
dimensional cross linkage structures.
Epoxy resins can be used continuously to 3000 F, but with special additions can
withstand a temperature of up to 5000 F.

PROPERTIES OF EPOXY RESINS

Good mechanical strength, less shrinkage and excellent dimensional stable after casting.

Exhibit Chemical Inertness.

High resistance.

Good adhesion to metals.

APPLICATION OF EPOXY RESINS

1. Epoxy resins are used in the middle of laminated insulating boards.
2. Dimensional stability prevents crack formation in castings.
3. They are also used as insulating varnishes.

46

CHAPTER-5
VACCUM PRESSURE IMPREGNATION PROCESS
BLOCK DIAGRAM OF VPI PROCESS

VACUUM
PUMP

NITROGEN
SUPPLY
TANK

VACUUM
TRAP

NITROGEN
LINE
VALVE

RESIN
SUPPLY
TANK

VACUUM
PUMP
VALVE

VACUUM
PRESSURE
IMPREGENT
ION TANK
RESIN
SUPPLY
VALUE

VACCUM PRESSURE IMPREGNATION PROCESS

The Vacuum Pressure Impregnation system was introduced by Dr. Meyer in
collaboration with Westing House in the year 1956. The resins used were of polyester
SIEMENS developed VPI system with EPOXY RESIN and treated accelerator VPI
system can be useful for manufacture of insulation and also windings are guaranteed to
expected quality. The stator coils are taped with porous resin poor tapes before inserting
into the slots of the cage stator. Subsequently wound stator is subjected to a special
47

process called VPI Process in which first the stator is vacuum dried and then impregnated
in a resin bath under a pressure of Nitrogen gas. Then the stator is curried in an oven. In
olden days Resin Rich System of insulation was used where the stator coils are wound
with Resin Rich tape which contains 40% of resin. But for good dielectric strength 25%
is required. The extra 15% of resin is to be oozed out which is a tedious process and is
carried out in medium. Hence it is not an ideal process is not employed
Now-a-days Resin Poor System is employed where the stator coils are wound
with Resin Poor tape which contains 8% of resin. For good dielectric strength, the extra
17% of resin is to be injected into the pores of the resin poor tape by impregnation and
is done by VPI Process.

RESIN MIXTURE
The resin used in VPI process is ET884, a mixture of Epoxy Resin E1023 and
Hardener H1006 in 1:12 rations by weight and the two components are mixed in 1:1
ratio. The resin tank contains Resin Mixture (Epoxy Resin + Hardener) and catalyst for
good insulation system.

RESIN
Resin is a polymer. The process of polymerization under condensation gives
Resin. The chemical name of resin is DIPHENOL PROPANE and its commercial
name is BISPHNOLA-A.

The chemical structure of Diphenol Propane is

(C6H50H)2C3H8.

HARDNER
Hardener is used to solidify the resin. Hardener means Anhydride which means
removal of water (i.e. H2O) molecule.

48

 CATALYST:
Catalyst is used to accelerate or decelerate the rate of a reaction. The catalyst
used in resin in the VPI process is Zine Napthenate.

5.1 STEPS INVOLVED IN VPI PROCESS

The different steps involved in the Vacuum pressure Impregnation process for
awound stator are:
HV Test.
Termination of the RTDs.
Preheating the job.
Shifting the job into the impregnation chamber.
Vacuum cycle.
Vacuum Drop test.
Heating of Resin.
Admission of Resin.
Resin Settling time.
Pressure Cycle.
Refilling of Resin.
Aeration.
Post Curing.
Cooling.

HV TEST:
The total wound stator which is brought from the stator assembly is subjected for
HV test before impregnation.

49

TERMINATION OF THE RTDs

All the salient RTDs in the straight portion and the body of the core are
terminated towards one side to monitor the temperature of the total winding.

PREHEATING THE JOB

The total wound stator is subjected for preheating to 60+30C in am oven for
duration of 12 hours.

SHIFTING THE JOB INTO THE HORIZONTAL CHAMBER

The impregnation chamber is to be kept clean without any traces of resin on the
resin inner side of the horizontal tank. If present, it reacts with moisture and scale
formation takes place. The resin traces present in the tank is wiped with methylene.

The total wound stator is lifted and shifted into a tub. The tub is shifted into the
impregnation chamber and the lid of the tank is closed by a hydraulic mechanism.

VACUUM CYCLE
The total wound stator is lifted and shifted into a tub. The tub is 60+30 C by
circulating hot brine solution through the surface of the impregnation chamber which is
heated up by heat exchangers. The vacuum pumps are switched on and vacuum is
created in the chamber up to 0.2 mbar. Then the total wound stator is subjected for
duration of 17 hours. Vacuum is created in the chamber to remove any moisture present
in the stator core and chamber as it greatly affects the dielectric strength of the insulation.
This is the most important factor considered during the manufacture and operation of the
generator.

50

VACUUM DROP TEST

This test is carried out at the end of vacuum cycle and before the admission of
resin. In this test all the vacuum pumps are switched off for 10 minutes and the vacuum
drop is measured. The vacuum drop should not be greater than 0.06mbar. If the drop is
greater than 0.06mbar, it suggests that there are some impurities present in the pores of
the insulation and the stator is again subjected for vacuum cycle for duration of 8 hours.

HEATING OF RESIN
All the resin tanks including the input pipelines of the resin are heated to 60+30 C.

ADMISSION OF RESIN
The valves of resin tanks are opened one after the other and the resin is filled
within 25-30 minutes into the tub due to difference in pressure i.e., resin in the resin tank
is at atmospheric pressure and the impregnation chamber is at 0.2mbar. During this time
there is a change in pressure inside the chamber and should not be more than 0.06mbar,
the vacuum will be created inside the chamber up to 0.2mbar. The level of resin should
be 100mmmore than the job height.

RESIN SETTLING TIME

Resin is allowed to settle for duration of 15 minutes such that all the air bubbles
are vanished.

PRESSURE CYCLE
The impregnation chamber is pressurized to 4kg/cm2 by dry. Nitrogen gas and
then the total wound stator is subjected for 3 hours.

51

REFILING OF RESIN

The resin remaining in the tub is filtered an sent back to the resin tanks.

AERATION
Here the pressure inside the impregnation chamber is made equal to that of
atmospheric pressure and the job is brought out.

POST CURING
The job is placed in the gas furnace. All the RTD terminals which are brought out
are connected to the temperature monitor for monitoring the post curing cycle. The total
wound stator is roated a t1rpm up to 1020 C, then the rotation is stopped.

The

temperature is now increased to 140=50C and the stator is subjected for 32 hours.

COOLING
The job is allowed to cool down to 800 C naturally. Now the furnace is opened
and epoxy red gel is sprayed on the overhangs to serve as anti fungus.

5.2 QUALITY CHECKS ON RESIN MIXTURE

The resin mixture is a combination of epoxy resin and hardener, the container of
which is stored in a cool and dry place and should be protected against humidity and
hence stored under vacuum below 200C., but chilled not below 80C. The impregnating
resin mixture is in the ratio of 100 parts of epoxy resin and hardener in a resin tank. The
epoxy resin and hardner are heated in an oven at 1750 C and sample is taken from every
drum to test before release. After thorough mixing the resin mixture is tested.

52

TESTS ON RESIN MIXTURE

Before beginning impregnation and after standstill period of more than 15 days,
the resin mixture is tested in the following manner:
The resin mixture is tested for viscosity at 600C and the limiting value is 50m
Poise above which the resin is rejected.
The resin is again tested for the increase in its viscosity at 600 C after 20 hours
heating at 1000 C. The maximum value at this point is 9m poise.
o After this resin is tested for the ester number which is the difference
between saponification number and total acid number.

Its maximum

limiting value is 10.

5.3 TESTING PERFORMANCE OF RESIN POOR SYSTEM

BEFORE IMPREGNATION PROCESS
The different tests that are carried out after laying the bars in the stator slots are:
Complete bottom layer high voltage test
Complete top layer high voltage test
Winding resistance measurement.
Mechanical run test.

BOTTOM LAYER TEST

After laying the bottom bars high voltage test is conducted with 1.5Up for One
minute, where Up=2Un=1. Up=Final test voltage. Un=Rated voltage of generator.

TOP LAYER TEST

After laying the top bars high voltage test is conducted with 1.1Up for one
minute, where Up=2Un=1.
53

INTER CONNECTION CHECKING

After completion of connection, winding and baking, high voltage test is

conducted with 1.05 Up for one minute. When one phase is under testing, the other
phases are earthed.

The measurement of resistance of individual phases gives the

checking of interconnection.

AC HIGH VOLTAGE TEST

After laying the top and bottom bars AC high voltage test carried out by
connecting all other phases to ground.

MECHANICAL AND ELECTRICAL RUN TEST

Dynamic test is carried out to find various losses. They are;

Mechanical losses
Iron losses
Copper losses

IMPREGNATION PLANT
Horizontal Impregnation Chamber for higher capacity stators of steam turbine or
gas turbine generators and Vertical Impregnation Chamber for small capacity systems
such as Permanent Magnet Generator stators for brushless excitation systems, coil
insulation of small pumps and armature of motors etc. are used.

RESIN RICH SYSTEM OF INSULATION

ADVANTAGES

1. Better quality and reliability is obtained.

54

2. In case of any fault the repair process is very easy.

3. Addition of excess resinis avoided.
DISADVANTAGES

It is very long procedure.1. Due to fully manual oriented process, the cost is more.

RESIN POOR SYSTEM OF INSULATION

ADVANTAGES

1. It has better dielectric strength and heat transfer coefficient.

2. Cost is very less and maintenance free.
3. Insulation life will be more and lifetime is about 540 years.
4. Reduction in time cycle and it gives high quality.

DISADVANTAGES

1. If any short circuit occurs, the repair process in difficult.2. There is need of excess resin

from outside.

55

COMPARISION BETWEEN RESIN RICH AND RESIN POOR

RESIN POOR SYSTEM

RESIN RICH SYSTEM

1) The insulating tape used in this system has

1) The insulating tape material used
only 8% of resin.

in this

system has 40% resin.

2) This method follows thermosetting process. 2) This method follows thermosetting process.

3) There is a need for addition OF resin from

3) Further addition of resin is not required from
outside

4) Reduction in time cycle for this process.

outside

4) It is very long process and time-consuming.

5) Tests are carried out while processing stage.

5) No tests are carried out here at processing
stage.

6) The cost of repairing is more.

6) Repairing work is easy.

7) Processing of stator bars is only possible in

Resin rich system.

7) Processing of bars along with stator and

processing of exciter coils (along with exciter
coil) are possible in resin poor.

8) The total cost of this process is more.

8) The overall cost is less compared to resin rich

system.

9) Windings are easy

9) Windings is difficult

10) Insulation strength decreases

10) Insulation strength remains almost same due to

more layers of insulation materials (tapes)
11) Cycle time is more

11) Cycle time is less

56

Finished Rotor with Retaining Ring

Complete finished rotor

57

CHAPTER-6
PERFORMANCE TESTING

TESTING OF TURBOGENERATORS

6.1 OBJECTIVES OF TESTING

Testing is the most important process conducted on a machine after it is designed,

to ensure that equipment concerned is suitable and capable for performing duty for which
it is intended & complies with the customer specifications.

Testing is done under

conditions as closely as possible to those which apply when the set is finally installed
with a view to demonstrate the customer its satisfactory operation. The tests provide the
experimental data like efficiency, losses, characteristics, temperature, limits etc, both for
confirmation of design forecast and as basic information for the production of future
designs. The machine performance is evaluated from the results of the equivalent tests.

ADVANTAGES OF TESTING

1. Provides data for optimization of design & quality assurance.

2. Meets the requirements of legal and contract requirements.
3. Reduction in rework cost.
4. Ensures process capability and develops check list.
5. Establishes control lover raw materials.

PERFORMANCE TESTS

The performance tests carried out on the turbo generator are classified as:
1.Mechanical run test.
2.Routine tests.
58

3.Type tests.

MECHANICAL RUN TEST

The generator should be run for 24 hours. This test is done to ensure that there
are no losses (friction and windage and the heat generated should be less. Vibrations
occurring in the generator are also detected.

ROUTINE TESTS

These tests are carried out on a generator to ascertain that it is electrically and
mechanically sound. The routine tests are classified as:
a. Static test.
b. Running test.

6.2 STATIC TEST

6.2.1 MEASUREMENT OF INSULATION RESISTANCE OF STATOR AND
ROTOR WINDINGS BEFORE AND AFTER HV TEST
Equipment:
i.

Megger (1000v/2500v)

ii.

Earthing rod and earthing wire or cable

IR of the stator and winding are measured separately & value are taken at 15 seconds
and60 seconds before and after HV test using megger of 2500V for stator and 1000V for
rotor windings.
Absorption coefficient of insulation is found out suing. Absorption coefficient=IR at 60

sec IR at 15 sec RMS value should be greater than or equal to 2. IF IR values are high,
the absorption coefficient is not considered because of early saturation.

With dry

windings its value will be somewhere in the vicinity of 2 or more. With damp windings
59

it decreases to one. Absorption coefficient of 1.8 & 1.7 may be satisfactory while a value
below 1.5 indicates a damp machine.
The minimum value if insulation Resistance (Rm) At 60 minutes is recommended as;
Rm= (KV=1) ohms where KV is voltage in kilovolts to be applied for test. In practice a
fairly high value is obtained .

6.2.2 MEASUREMENT OF POLARIZATION INDEX OF STATOR

WINDING

The polarization index of stator winding, all the three phases together, is measure
during 2500v megger after HV test. The IR values are noted at one minute and ten
minutes from starting of the measurement. The minimum allowable value of PI is 2.0
The value of Polarization Index is valuated as< P.I = IR value at 10 min IR value at 1
min
High Voltage Test
Equipment
:i. Voltmeter.
ii.Binding 50 HZ AC High voltage transformer and its induction regulator (or) input
autotransformer.
iii.Potential Transformer (35 or 100KV/100V).
Iv. Wire.
v. Ear thing rod and Ear thing Wire (or) cable.
When HV test is done on one phase winding, all other phase windings, rotor
winding , instrumentation cables and stator body are earthed. High voltage is applied to
the winding by gradually increasing to the required values and maintained for 1 min and
reduced gradually. The transformer is switched off and winding is earthed by connecting
into ear thing rod connected to earth wire. The test is conducted on all the phase & rotor
winding separately.

60

HV test levels
Stator winding: (2Ut= 1) KV=23 for 11 KV machines Rotor winding: 10Up volts
(with min of 1500V and 3500V) where Ut=Rated Voltage of machine under test Up=
Excitation voltage

6.3 RUNNING TESTS

6.3.1MEASUREMENT OF SHORT CIRCUIT CHARACTERISTICS

The machine is prepared for short circuit characteristic using current transformers
and shorting links. The machine is run at rated speed and dive motor input voltage and
current are noted and is excited gradually in steps of 20%,40%,60%,80%,90%,100% In
(rated current) At each sep the following parameters are noted:

Stator current (Ia & Ib)

Rotor current (If) corresponding to stator current

Drive motor voltage (Vd) and current (Id) corresponding to stator current.

6.3.2 MEASUREMENT OF MECHANCIAL LOSSES, OPEN CIRCUIT

CHARACTERISITICS

The machine is run at rated speed and drive motor input voltage and current are
noted and machine is excited

gradually in steps of 20% En (En=rated voltage of

machine) At each step the following parameters are noted.

Stator Voltage (Vab, Vbc, Vca).

Rotor current (If) corresponding to stator voltage.

Drive motor voltage (Vd) and current corresponding to stator Voltage. The excitation is
reduced and cutoff, the speed is reduced and the machine is cooled at lower speed. The
temperatures are checked using RTDs. The machine is stopped when it is sufficiently
cooled down (stator core temperature should be less than 600C. From the above data,
characteristic curves are plotted as follows:
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En (vs) if

En (vs) machine losses in KW

6.4 TYPE TESTS

The tests are conducted for customer satisfaction. The different type tests done
are:

BDV (Brad Down Voltage)

Tand Test

Voltage regulation.

Over hang vibration.

BDV (Break down voltage) test

Break down voltage at which the insulation breaks down. This test is conducted
to check the reliability and life of the insulation.

Tand test
Equipment:
i.

Schering bridge.

ii.

50 HZ HV transformer

iii.

100-1000 PF Standard capacitor.

iv.

Isolation shunt box.

v.

High tension cable.

vi.

Earth cable.

vii.

Voltmeter

viii.

Megger (2 KV)

ix.

Null indicator

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The test is conducted to check the presence of impurities in the insulation. Tand value is
significant factor for testing dielectric strength of the insulation. D is loss angle. The
stator body, is isolated from ground by placing insulation package between body and
phase connections to the Schering Bridge. HV Supply is switched on and the bridge 1.0
Un in steps of 0.2 Un. By varying the voltage, Tand value for each phase and also for
combined phases is noted down. Tand value should be generally less than or equal to 2%

Voltage regulation
Voltage regulation is defined as the change in voltage from no load to full load
expressed as the percentage of full load. For generator to be ideal and efficient, voltage
regulation should be less. There are four methods to find voltage regulation.
They are:
i.

EMF method

ii.

MMF method

iii.

ZPF method

iv.

ASA method

Overhang vibration test

This test is conducted to check the rigidity and life of the overhang portions of the
stator windings.

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CONCLUSION
Vacuum Pressure Impregnation technology can be used in a wide range of
applications from insulating electrical coil windings to sealing porous metal castings. It
normally produces better work in less time and at lower cost than other available
procedures. VPI yields superior results with better insulation properties, greater overall
reliability and longer life. VPI reduces coil vibration by serving as an adhesive between
coil wires, coil insulation and by bonding coils to their slots. As todays world is
concentrating on reliability, maintainability, cost reduction and time cycle reduction, the
leading manufacturers in the world are adapting VPI system of insulation for generators
up to 400 MW with hydrogen cooling VPI system of insulation for electrical, mechanical
and chemical properties and is highly reliable.

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SCOPE OF THE FUTURE

In view of the above, in the coming decades, the Indian grids will use more of
generators using VPI system of insulation. In the scenario of world market which
demands generators with less cost at the best possible time with better reliability VPI
system of insulation will provide viable solution compared to Resin Rich type of
insulation system.

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