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GENERATOR

The document discusses generators used in power plants. It notes that generators are the most critical equipment and outlines standards and testing procedures to maximize reliability. Failure to properly operate and maintain generators can lead to increased outages. The document provides details on generator design parameters, components, cooling methods, capacity ratings, reliability factors, common failures and recommended tests to evaluate condition.

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harisankar
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54 views34 pages

GENERATOR

The document discusses generators used in power plants. It notes that generators are the most critical equipment and outlines standards and testing procedures to maximize reliability. Failure to properly operate and maintain generators can lead to increased outages. The document provides details on generator design parameters, components, cooling methods, capacity ratings, reliability factors, common failures and recommended tests to evaluate condition.

Uploaded by

harisankar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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GENERATOR

INTRODUCTION

1
GENERATOR
 MOST CRITICAL EQUPT IN POWER PLANT
 OUTAGE WILL DRASTICALLY REDUCE
PLF/NON AVAILABILITY OF POWER
 OLD POWER PLANTS POSE FREQ. PROB.
 PROPER O&M PRACTICE WILL
MINIMISEFAILURES/OUTAGES

2
Generator
GENERATOR DESIGNED TO WITHSTAND

 RATED PARAMETERS
 ABNORMAL LOADS FOR SHORT DURATION
 VIBRATION
 STRESS /STRAIN due to magnetic forces
 HEAT CYCLIC
 CONTINUOUS RUNNING WITH FULL LOAD

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GENERATOR
STANDARDS

IEC 34 -1 Rotating elec.m/cs


34 -2 rating &performance
34 -3 methods for determi.
ning losses & eff.from
tests
IS 5422

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GENERATOR

NO. OF HOURS OPN EXPECTED

2 LAKHS HOURS ( 23 years)


(2,00,000 HOURS)

NO OF START& STOP CYCLE

10000 NOS

5
GENERATOR

SPECIFIC WEIGHT

2.5 KG TO 3.0 KG /KVA - LOW CAPACITY

0.5KG TO 1.0 KG /KVA – HIGH CAPACITY

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GENERATOR

CAPACITY /RATING

D2. L. n. B. AC

D(rotor) not greater than 1.5 m


L 10.OM
B 1.5 to 1.9 TESLA
d (AC) 1000 to 1200 A/SQ.CM
(300 TO 800 A/SQ.CM FOR LOW &MEDIUM
CAPACITY UNITS)
magnetic permeability test B up to 2.2 TESLA

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GENERATOR
TYPES OF GENERATORS
(R) (S) COOLIG MEDIUM CAPACITY
TLII Air Air (indirect) 10 -50 MW
T L R I Air Air (radial) 30-300MW
T H R I H2 H2 (radial) 150-450MW
T H D D H2 H2 (axial ) 400-1000MW
T H D F H2 H2O(axial) 550-1500MW/1900
T H F F H2O H2O 1000- 2000MW

Direct conductor cooling RADIAL FLOW- PERPENDICULAR TO CONDUCTOR


Axial FLOW- PARALLEL TO CONDUCTOR

UPTO 1500MVA 2 POLE MACHINE

1900/2200 MVA 4 POLE MACHINE (NUCLEAR STATION)

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GENERATOR

TREND OF DEVELOPMENT

AIR COOLED UP TO 200/250 MVA

HYDROGEN COOLED UP TO 450 MVA

HYDROGEN &WATER COOLED UPTO 1500 MVA

210-235-250-500-600-660-800-1000 MW T.Gs

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GENERATOR

1831 - FARADYS EMI


1888 - CHARLES PARSON Ist AC TG
1938 - 20 TO 30 MW
1945 - 30 TO 60 MW
1958 -65 100 TO 120 MW
1965-70 200-210-235-500 MW
1990 250 MW
2000-10 600/660/800/1000MW
FUTURE TREND 1000- 1600MW

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GENERATOR
210 MW TURBO GENERATOR

247 MVA, .85 LAG, 60SLOTS/36 SLOTS


56 TO 60 M3, SCR 0.49,
H2 Pr.3 TO 3.5 KSC
15.75 KV, 9050A, 310V-2600A
THW TYPE, STATIC EXCITATION
RING TYPE SEAL OIL SYS. 2POLE, 50HZ
MVAR +70 ------ -130 (LAG)
EFF. 98.7% 60 RTDs FOR STATOR SLOTS 12 FOR CORE/IRON TEMP
AIR GAP 70 TO 80 MM,15.5/89.6 milli ohms
Slip ring dia 460mm
BRUSHES HM6R-HM100-LFC557 (FREE FROM DUST OIL VAPOURS)
COLD GAS-44degree celcius(37-44), Distillate45 (35-45)
WDGS/CORE STATOR 105 ROTOR 110-115
OCC/ SCC 917A/1875A
CLASS OF INSULATION F 155degree Celsius

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GENERATOR
RELIABILITY DEPENDS ON

DESIGN, TECHNOLOGY,MANUFACTURE
O&M PRACTICES

R proportional to MTBF/MTBF+MDT
MDT - FAILURE

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GENERATOR
CAUSES OF FAILURES

TEMPERATURE
THERMAL CYCLING, THERMAL STRESS
VIBRATION
AGEING
ABNORMAL PARAMETERS
CORROSION,WEAR &LOOSENESS
ENVIRONMENTAL CONDITIONS
OVER LOADS

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GENERATOR

ABNORMAL REGIME OPERATIONS


TRANSIENT EVENTS
ASYNCHRONOUS OPERATION
INSULATION DETERIORATION
INSUFFICIENT COOLING
NO.OF OPERATING HOURS
NO OF START/STOP
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GENERATOR
MAJOR CONTRIBUTING FACTORS FOR AGEING.

LOW CYCLE FATIGUE


(due to start/stop cycle& cyclic loading)

HIGH CYCLE FATIGUE & VIBRATION


(due to speed of rotation & vibration)

THERMAL CYCLING
(VARIATION OF TEMP DURING OPN CAUSES DIFF LEVEL OF EXPANSION
AND CONTRACTION AND THUS CAUSING THERMAL STRESS LEADING
TODEFORMATION/CRACKS)

CORROSION,WEAR AND LOOSENESS

OPERATING CONDITIONS AND ENVIRONMENTS

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GENERATOR
COMMON SERIOUS TROUBLES IN T.G
AND
CONTRIBUTING FACTORS
serious troubles factors
 ROTOR FRACTURE 1,2
 RETAINING RINGFRACTURE 1,4
 FAULT OF ROTOR WEDGE 1,5
 BREAKAGE, DEFORMATION
OF ROTOR WINDING 1,2,3,4

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GENERATOR

 FAULTOF ROTOR WINDINGTERMINAL


BOLT 3
 ROTOR WINDING LAYER
SHORT/GROUNDING 3
 EXESS SHAFT VIBRATION 2,4,5
 FAULT OF COLLECTOR RING 4
 FAULT OF ROTOR SURFACE 5
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GENERATOR

 BURNING,FAILURE OF STATOR CORE END


2,3,4
 INSULATION DAMAGE OF STATOR WDG
IN SLOTS 2,3,4
 INSULATION OF STATOR END
WDGS DAMAGE 2,3,4
 PHASE CONNECTION BAR FAILURE
OF STATOR WDG 3,4
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GENERATOR
 WATER COOLING PARTS FAULT IN STATOR WDG 3,4
 OVER HEATING OF STATOR WDG TERMINAL LEAD 4

 1.LOW CYCLIC FATIGUE DUE TO START AND STOP


 2.HIGH CYCLIC FATIGUE DUE TO ROTATION AND
VIBRATION
 3. FATIGUE DUE TO HEAT CYCLE
 4. CORROSION,WEAR,LOOSENESS
 5.CHANGE OF ENVIRONMENT&OPERATING CONDITION

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GENERATOR
 FAILURE ANALYSIS (method)

DATE AND YEAR OF INSTALLATION


NO.OF RUNNING HOURS
NO. OF STARTS & STOPS/TRIPS
NO. OF ELECTRICAL FAULTS
VISUAL INSPECTION
ND TESTS TO IDENTIFY THE FAULT

20
GENERATOR

TESTS ON GENERATOR
TEST PURPOSE ITEM
IR, PI DETECTS SERIOUS STATOR
FLAWS,MOISTURE &
ABSORPTION& CLEAN ROTOR
LINESS OF WDGS WDGS
DRY OUT IMPROVE INS QUALITY BOTH
S&R

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GENERATOR

TAN DELTA EVALUATION OF STRESS S


GRADING ,DIELECTRIC
LOSSES

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GENERATOR

DC WDG DETECTS POOR S,R


RESIST CONNECTIONS wdg
ANCE & CONDUCTOR
SHORTS

VARIATION SHOULD BE LESS THAN 2%

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GENERATOR
PARTIAL DISCHARGE/CORONA

EVALUATION OF STESS GRADING


SYSTEM AND LOCATION OF PD SITES

STATOR WINDING

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GENERATOR

DC LEAKAGE CURRENT TEST

DETECT INSULATION WEAKNESS

STATOR WINDING

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GENERATOR

DIGITAL ELCID TEST

DETERMINES HEALTHINESS OF STATOR


CORE INTER LAMINAR INSULATION

STATOR CORE INSULATION

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GENERATOR

AC IMPEDENCE TEST ON ROTOR WDG


DETECTS THE PRESENCE OF SHORT
impedance should not vary by more than
10% from rated speed to zero speed
V/I = Z

27
generator

wedge tightness check

DETERMINES WEDGE TIGHTNESS

STATOR WEDGES

28
GENERATOR

RECURRENT SURGE OSCILLOGRAPH (RSO)


OR
GROWLER TEST - ROTOR WDG

DETECTS INTER TURN/E.F IN WINDING

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GENERATOR

METALLURGICAL TEST ON ROTOR


RETAINING RINGS DP & UT

DETECTS SURFACE AND SUB SURFACE


CRACKS

30
GENERATOR
OPEN CIRCUIT CHARACTERISTICS TEST

SHORT CIRCUIT CHARACTERISTICS TEST

SHORT CIRCUIT RATIO

PHASE SEQUENCE TEST

31
GENERATOR

32
33
Generator

34

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