Generator

Phase 2B - Heidenheim

Electrical design | Heidenheim | 2016-10-19 1

Proprietary Information:
This document and the information contained herein is the property of Voith Hydro. No
exploitation, use or reproduction of any information contained herein is permitted without the
written consent of Voith Hydro.

Generator Electrical design | Marcus Svanberg | October 2016 2

© Voith Hydro
Course Overview

This training will provide participants with basic knowledge of

generator and excitation system.

Generator Electrical design | Marcus Svanberg | October 2016 3

© Voith Hydro
Course Topics- Generator design

1. Electrical Design
2. Stator winding
3. Stator
4. Rotor
5. Bearing

Generator Electrical design | Marcus Svanberg | October 2016 4

© Voith Hydro
Instructor(s)

Marcus Svanberg, Ph.D.

Electrical design Engineer, VHEC-VHV
Marcus has held various Engineering positions
for the past 16 years, 3 with Voith. Engineering
roles include: generator electric design,
ventilation and cooling, rehabilitation, site
testing. The work covers the tendering phase,
delivery projects and R&D.
Apart from Voith, Marcus have worked for
E.ON, Alstom and ABB.

Generator Electrical design | Marcus Svanberg | October 2016 5

© Voith Hydro
Topic – Electrical design
1. Terminology
2. Voltage induction at no load
3. Winding factors, air gap flux and pole shoe shape
4. Analogy electricity vs. magnetism
5. Magnetic circuit, iron saturation
6. Excitation current at load
7. Losses
8. Magnetic forces

Generator Electrical design | Marcus Svanberg | October 2016 6

© Voith Hydro
Learning Objectives

1. Voltage build-up equation

2. Calculating the excitation current
3. Losses
4. Magnetic forces on the stator and rotor

Generator Electrical design | Marcus Svanberg | October 2016 7

© Voith Hydro
Topic – Electrical design
Some terminology

The stator has Q slots and p pole pairs.

Each pole have Q/(2p) slots.
For a three phase generator each pole has q=Q/(2p*3) slots per pole and
phase.
For a normal two layer winding (two coil sides per slot) the slot has ns
conductors per slot. Single turn coil -> ns=2, two turn coil -> ns=4 etc.
Coils under one pole and phase is connected in series (q*ns/2 pcs.) and form a
coil group. The number of coil groups per phase is the same as number of
poles.
Coil groups can be connected in series or parallel according to certain
symmetry conditions. The number of parallel circuits per phase is denoted c.
The number of series connected turns per phase is p*q*ns/c.

Generator Electrical design | Marcus Svanberg | October 2016 8

© Voith Hydro
 Topic – Electrical design
Induction at no load
B N
  Dsi
p   180el
2p


0 N  S 2 S
q  2 slots / pole & phase
ns  2 No. conductors / slot

 d Nˆp p  1 No. pole pairs

v fas    N  V phase,rms 
t dt 2
2 qns
qn => V fas  p f w  B 1 p L 
N  p s f w Winding turns/phase  2 c
c
ˆ 2 2 qns
p  B  A  B 1   p L Flux/pole  f f w  B 1 Dsi L
   2 c
Area of
Average of pole pitch
sinus shaped B
”Voltage build-up equation”
Generator Electrical design | Marcus Svanberg | October 2016 9
© Voith Hydro
Topic – Electrical design
The generator expr. gives Bδ from a chosen geometry and winding

Generator Electrical design | Marcus Svanberg | October 2016 10

© Voith Hydro
Topic – Electrical design
Resulting winding factor

f w  f distr  f pitch  f x
f distr : distribution over sevral slots (q  1)
f pitch : coil pitch
f x : slot or pole skewing , pole displacement , etc.
Mt Coffee :
q  3 slots/pole & phase
coil pitch  8 (89%)
no slot skewing etc.
f w1  0.960  0.985 1  0.946

Generator Electrical design | Marcus Svanberg | October 2016 11

© Voith Hydro
Topic – Electrical design
Induction (Winding factors)

Generator Electrical design | Marcus Svanberg | October 2016 12

© Voith Hydro
Topic – Electrical design
Induction (Winding factors)

Sum without
winding factors

Sum with
winding factors

Generator Electrical design | Marcus Svanberg | October 2016 13

© Voith Hydro
Topic – Electrical design
Induction (Design of the pole shoe)
Improvement of the wave shape can be achieved by changing
the pole shoe design.
k B  0,9
B
kB   1,03
B 1

Concentric part

Chamfer

Sinus pole shoe

Generator Electrical design | Marcus Svanberg | October 2016 14

© Voith Hydro
Topic – Electrical design
Analogy Electricity Magnetism
U = R·I ↔ Um = N·I = R·Ф

J = σ·E ↔ B = μH

Current density J [A/m2] ↔ Flux density B [Wb/m2=T]

Current I [A] ↔ Magnetic flux Ф [Wb]

Resistance R = (1/σ)·(L/A) [Ω] ↔ Reluctance R = (1/μ)·(L/A) [1/H]

Conductivity σ [S/m] ↔ Permeability μ [H/m]

Conductance G = 1/R [S] ↔ Permeance P = 1/R [H]

Voltage (emf) U [V] ↔ Magnetomotive force (mmf) N·I [A]

Electric field strength E [V/m] ↔ Magnetic field strength H [A/m]

- μ is non-linear and depends on B for magnetic mtrl. (Ex. electrical steel), σ is constant
- Current through resistance→Energy loss, Magnetic flux through reluctance→Energy storage

Generator Electrical design | Marcus Svanberg | October 2016 15

© Voith Hydro
Topic – Electrical design
Magnetic circuit 
Flux densities are calculated B Reluctance grid
A air gap
R yoke
Rtooth Rtooth
Byoke Rslot Rslot
Btooth
Bd Rair gap Rleak Rair gap

Bpole Bleak leak

  tot
NfIf NfIf
 
Brotor rim R pole R pole
Rrotor rim

tot  air gap  leak

Generator Electrical design | Marcus Svanberg | October 2016 16

© Voith Hydro
Topic – Electrical design
Magnetic circuit
With magnetic fluxes known and meterial curves the field current at
no load, ifo, can be calculated as: Excitation requirement

H    kc  H toothltooth  H polel pole  0,5( H yokel yoke  H rotor rim lrotor rim )  N f i fo

B BX
H  HX 
0 0  X
x  stator tooth
stator yoke
rotor pole
rotor rim

Generator Electrical design | Marcus Svanberg | October 2016 17

© Voith Hydro
Topic – Electrical design
Magnetic circuit
kc is Carters factor taking into account ”fringing” at the open
stator slots
(and also ventilation ducts).

Typically kc = 1.05-1.20

Generator Electrical design | Marcus Svanberg | October 2016 18

© Voith Hydro
Topic – Electrical design
Magnetic circuit
The pole flux is greater than the air gap
flux due to pole leakage

rotor  (1   )air gap

where   10 - 20%

Generator Electrical design | Marcus Svanberg | October 2016 19

© Voith Hydro
Topic – Electrical design
Magnetic circuit
From the magnetic circuit calculation you get the no load curve for
the machine. Tomgångskurva
No load curve
1,4

1,3 Air gap line

Normally 1,2

1,1 Um UmFe

U m 1

 0,9
voltage [p.u.]
[pu]
0,9

U m  U mFe Huvudspänning 0,8

0,7

0,6
Line

0,5

0,4

0,3

0,2

0,1

0
0 0,5 1 1,5 2 2,5 3
FieldFältström
current [pu][p.u.]

Generator Electrical design | Marcus Svanberg | October 2016 20

© Voith Hydro
Topic – Electrical design
Magnetic circuit
The excitation current at an arbitrary load point (if,load) is calculated
from the Potier reactance XP (IEC 60034-4, ASA diagram)

i f .load  i f  i f ,g  i f ,k sin    i f ,k cos  

2 2
A

EP  U  U Xp sin    U Xp cos  
2 2
V 

U Xp  I 3 X P V 

if,g = field current air gap line (at stator voltage U)

if,k = field current armature reaction (at stator current I)
cos = power factor
Ep = voltage at which iron saturation is evaluated
UXp = voltage drop over Potier reactance (at stator current I)

Generator Electrical design | Marcus Svanberg | October 2016 21

© Voith Hydro
Topic – Electrical design
Losses
• No load losses
• Brush friction, pump motors (running continuously)
• Bearings
• Ventilation (”windage”)
• Iron
• Load losses (at 75°C)
• Stator winding I2R
• Additional load losses
• Excitation losses (at 75°C)
• Rotor winding If2R
• Exciter losses

Generator Electrical design | Marcus Svanberg | October 2016 22

© Voith Hydro
Topic – Electrical design
• Iron losses – at no load test
• Iron losses from main flux: stator teeth and yoke
• Additional losses at no load in
– Pole shoe surface and damper winding
– Stator winding from magnetic flux leakage in slots
• Stator winding I2R: R = Cul / ACu
• Additional load losses due to
• Circulating currents within and between stator winding strands
• Pole shoe surface and damper winding
• Conducting objects outside stator core (pressure fingers, -plates etc.)
• Rotor winding If2Rf: Rf = Cul / Af,Cu
• Exciter losses
• Static exciter (incl excitation transformer)
• Brushless exciter (small generator)

Generator Electrical design | Marcus Svanberg | October 2016 23

© Voith Hydro
Topic – Electrical design
Magnetic forces (Excentricity)
For an ideal built machine there are no excentricity forces (=one sided pulling
force). But nothing is ideal...

Smaller air gap than nominal

•Excentricity force gives a negative  min    e
stiffness to the shaft system which
lower the critical speed. Larger air gap than nominal
 max    e

•For a weak shaft system a large

F1
excentricity force can cause the F2 Fnet=F1+F2+F3+F4+F5+F6+F7+F8
F8
rotor and stator to collide.
F3
F7

F6 F4
Fnet
F5

Generator Electrical design | Marcus Svanberg | October 2016 24

© Voith Hydro
Summary of Topics for this Module

1. Voltage build-up equation

2. Calculating the excitation current
3. Losses
4. Magnetic forces

Generator Electrical design | Marcus Svanberg | October 2016 25

© Voith Hydro
Review Learning Objectives

1. Terminology
2. Voltage induction at no load
3. Winding factors, air gap flux and pole shoe shape
4. Analogy electricity vs. magnetism
5. Magnetic circuit, iron saturation
6. Excitation current at load
7. Losses
8. Magnetic forces

Generator Electrical design | Marcus Svanberg | October 2016 26

© Voith Hydro
Contact:
Marcus Svanberg, Ph.D.
Voith Hydro AB
Tel. +46 70-20 22 610
marcus.svanberg@voith.com

Generator Electrical design | Marcus Svanberg | October 2016 27

© Voith Hydro