POWER

POWER PRODUCTION

TURBINE

GENERATOR

THERMAL GAS STATOR ROTAR EXICITER

COMPRESSORS

POWER CONSUMER

COMPRESSORS

PIPE CONDENSORS

POWER GENERATION.

POWER TRANSMISION
STEPUP
POWER DISTRIBUTION
STEP DOWN

COUSTOMERS USE

BULB FAN COOLERS IRONBOX TAPES FACTORIES etc

GENERATOR

STATOR
EXCITER

CORE
RTD
ARMATURE

ROTOR

WINDING

FORGING

WINDING

YOKE

TESTING PROCESS
MANUFACTURE

ASSEMBLING

GENERATOR

PERFORMANCE

READY FOR PRODUCTION

INTRODUCTION
It is a well-known fact that all power plants are located in such a place where
there are lots of resources. For example THERMAL POWER PLANTS near coal
resources, HYDRALPOWER PLANT where there is lot of water is present.

As we all know that in KOTHAGUDAM we have we have one THERMAL power

plant. There we have TURBINES, BIOLERS, COMPRESSORS, CONDENSERS
and GENERATORS. We need all these Machines to produce POWER.

We need coal to produce steam, Steam helps to rotate the turbine, turbine will
be rotating the shaft of the rotator and in turn exciter is also been rotated to
produce power. Boiler is used to produce steam for rotating turbine

GENERATOR

TURBO GENERATOR
The Generator consists of the following components:

STATOR
Stator Frame,
Stator Core,
Stator Winding,
Generator Coolers,
Stator End Covers.

R O TOR
Rotor shaft,
Rotor winding,
Rotor Retaining Ring,
Field Connections.

EXCITER
Design features,
Rectifier wheels,
Field Connections.

BEARINGS

SKID

TESTING PROCESS
During manufacturing process,
D u r i n g As s e m b l i n g ,
Performance test.

BREAKERS

NOTES ON GENERATOR
INTRODUCTION
Types of Generators
GENERATOR BEARINGS
The generator rotor is supported at two journal bearings. The bearings
consist of a bearing pedestal and bearing shell is split into two halves to facilitate
assembly. The bearing pedestals are iron castings and the bearing shells are
steel castings. The bearing pedestal is provided with a spherical seating surface
and the bearing shell rests in it with its outer spherical surface. The inner surface
of bearing shell is provided with spiral grooves and cast with Babbitt metal.

Bearing Oil Supply:

The oil required for bearing lubrication and cooling is
obtained from the turbine oil supply system and supplied to the
lubricating groove in the bottom-bearing sleeve. The upper
bearing sleeve consists of a wide over flow groove through
which oil is distributed over the shaft journal and fed to the
lubricating gap.

Bearing Temperatures:
The temperature of each bearing is monitored by one double-element
RTD. The RTD is screwed in position on side of the lower bearing sleeve from
outside with the detector extending to the Babbitt liner.

STATOR
INTRODUCTION:
Stator frame is of welded construction, supports the core and the windings. It
consists of air duct pipes and radial ribs, which provide rigidity to the frame.
Footings are provided to support the stator on the skid. The
stator frame should be rigid due to the various forces and
torques during operation. The welded stator frame consists of
two end plates, axial and radial ribs. The arrangement and
dimensioning of the ribs are determined by the cooling air
passages, the required mechanical strength and stiffness. The
end covers are aluminium alloy castings. The stator frame is
fixed to the skid with the help of hexagonal bolts. The skid is
interim fixed to the concrete foundation through foundation
bolts.

Stator core:
The core packed into the stacking frame is pressed firmly together
between the end plates of the machine frame and fixed in this position by welding
the axial ribs of the core and the end plates of the frame. End fingers on the
inside diameter of the end plates transmit the pressure to the teeth of the core.
The compressive force produced prevents the laminations and teeth from
vibrating. An eye is welded to each end plate for attaching suitable lifting gear
with adequate lifting capacity for transporting the complete machine. All the
forces that occur during normal operation or on short circuits are transmitted from
the stator yoke to the base frame via the seating plates and into the foundation.

Location of Bars:
A

semi-conducting

wrapper

of

graphite

paper

in

the

slot

p r o t e c t s t h e b a r. T h e s t a t o r w i n d i n g i s p r o t e c t e d a g a i n s t t h e
e f f e c t s o f c u r r e n t f o r c e s i n t h e s l o t s e c t i o n . To e n s u r e t i g h t
seating of the bar at the slot bottom, a slot bottom-equalizing
strip of press path is inserted. A top ripple spring is arranged
between two compression strips to exert a continuous pressure
on the bars. The bars are shaped so that, cone shaped end
windings are obtained. In order to reduce the stray losses a
small cone taper of (13-20 ) is used. On the wide sides of the
bars spacers of insulating material are inserted at regular
intervals.

Bearings :
The rotor runs in two floating type guide bearings, designed as pedestal
bearings, with forced oil or oil-ring lubrication. The driven end bearing is secured
to the base frame and insulated from the latter. As the connections are designed
to prevent short-circuiting of the insulation.

Enclosure :
The enclosure consists of the inner and outer components. The inner
components comprises of the winding covers, which form an angular enclosure
of the overhang of the stator winding and are also used as air ventilator rings.
The outer enclosure consists of top and bottom parts and is designed as required
for the particular degree of protection, as indicated in the dimension drawing or in
Technical data. The ventilating circuit is of the double - ended symmetrical
arrangement.

STATOR CORE:
Stator core is stacked from insulated electrical sheet laminations and suspended
in the stator frame from insulated dovetailed guide bars. Axial compression is
obtained from clamping fingers, clamping plates and non-magnetic clamping
bolts which are insulated from the core. In order to minimize the hysterics and
eddy current losses of the rotating magnetic flux which interacts with the core.
The entire core is built up of laminations, each layer of which is made from a
number of individual segments. The segments are punched from silicon steel. In
the outer circumference the segments are stacked in insulated trapezoidal guide
bars, which hold them in position. The guide bar is not insulated to provide for
grounding the core. The laminations are hydraulically compressed and heated
during the stacking procedure. The complete stack is kept under pressure and
fixed in the frame by means of cell

STATOR
Stator frame is of welded construction, supports the core and the windings. It
consists of air duct pipes and radial ribs, which provide rigidity to the frame.

STATOR
Stator frame is of welded construction, supports the core and the windings .It
consists of air duct pipes and radial ribs, which provide rigidity to the frame.
Footings are provided to support the stator on the skid. The stator frame should
be rigid due to the various forces and torques during operation. The welded
stator frame consists of two end plates, axial and radial ribs. The arrangement
and dimensioning of the ribs are determined by the cooling air passages, the
required mechanical strength and stiffness. The end covers are aluminium alloy
castings. The stator frame is fixed to the skid with the help of hexagonal bolts.
The skid is interim fixed to the concrete foundation through foundation bolts.

Electrical Connection of Bars and Phase Connections:

Brazing makes Electrical Connection of Bars: Electrical connection
between the top and bottom bars, one top bar being brazed to associated bottom
bar. The coil connections are wrapped with tapes. The thickness of the wrapper
depends on the machine voltage. After taping, an insulating varnish is applied.

Phase Connectors: The phase connectors consist of flat copper sections, the
cross-section of which results in a low specific current loading. The connections
to the stator winding are of riveted and soldered type. The phase connectors are
wrapped with resin-rich mica tape, which contain synthetic resin having very
good penetration properties. The phase connections are then cured at a certain
temperature, with the shrinking tapes contracting so that a void free insulation is
obtained.

Output Leads:
The beginning and ends of the three phase windings are solidly bolted to
the output leads with flexible. The output leads consist of flat copper sections
with mica insulation. To prevent eddy-current losses and inadmissible
temperature rises; the output leads are brought out through insulating plates.

ROTOR
Introduction:
R O TOR W I N DI N G
Construction:
The field winding consists of several series connected coils inserted into
the longitudinal slots of the rotor body. The coils are wound so those two poles
are obtained. The solid conductors have a rectangular cross-section and are
provided with axial slots for radial discharge of the cooling gas. The individual
conductors are bent to obtain half turns. After insertion into the rotor slots, these
turns are combined to form full turns of series connected turns of one slot
constituting one coil. The individual coils of the rotor winding are electrically
series connected so that one north and one south magnetic pole are obtained.

Insulation:
The insulation between the individual turns is made of layers of glass fiber
laminate. The coils are insulated from the rotor body with L shaped strips of glass
fiber laminate with Nomex interlinear. The strips are provided with axial slot of the
same cross- section and spacing as used on the rotor windings.

Rotor Slot Wedges:

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 an
alloy of high strength and good electrical conductivity, and are also used as
damper wedged bars. The retaining rings act as short circuit rings to induced
currents in the damper windings.

ROTOR SHAFT:
The rotor shaft is forged from a vacuum cast steel ingot. The high
mechanical stresses resulting from the centrifugal forces and short circuit

torques call for high quality heat-treated steel. The rotor consists of an
electrically active portion and two shaft ends. Approximately 60% of the rotor
body circumference has longitudinal slots, which hold the field winding. Slot pitch
is selected so that 180 displace the two solid poles. The rotor wedges act as
damper winding within the range of the winding slots. The rotor teeth at the ends
are provided with axial and radial holes, enabling the cooling gas to be
discharged into the air gap after, intensive cooling of the end windings.

COOLING OF ROTOR WINDINGS:

Each turn is subdivided into four parallel cooling zones.
One cooling zone includes the slot from the center to the end of
t h e r o t o r b o d y, w h i l e a n o t h e r c o v e r s h a l f t h e e n d w i n d i n g t o t h e
c e n t e r o f t h e r o t o r b o d y. T h e c o o l i n g Ai r f o r t h e s l o t p o r t i o n i s a
limited into the slot bottom ducts below the rotor winding. The
hot gas at the end of the rotor body is then discharged into the
air gap between the rotor body and stator core though radial
openings in the conductors and in the rotor slot wages. The
cooling air for the end winding is drawn from below the rotorretaining ring. It rises radically along the individual coils and is
then discharged into the air gap via axial and radial slots in the
end portions of the rotor teeth.
Direct Cooling: Usually use in the rotor to eliminate hotspots and differential
temperatures between adjacent components, which would result in mechanical
stress particularly in the copper conductors.
Indirect Cooling: Used for stator windings.

AIR COOLING CIRCUIT:

Air is circulated using two axial flow fans arranged in the rotor shaft. The fans
draw cold air from the cooler unit, which is divided, into 3 flow paths.
1.

It is directed into rotor end winding space. Part of it also flows over the
individual coils for cooling in the rotor end winding and then leaves the end
windings via the bores in the rotor teeth. Other part flows from the rotor
end winding space into slot bottom ducts. From this it will discharge into
the air gap via radial ventilating ducts.

2.

Air is directed over stator end windings to the air ducts into the space
between the generator housing and the stator core. Then air flows into the
ventilating slot of the stator core, where it absorbs heat from the stator
core and stator windings.

3.

It is circulated into the air gap via the rotor-retaining ring. The air then
mixes with the hot air flowing via ventilating ducts in the stator core into
the outer hot air compartment in the stator frame for being returned to the
cooler.
The three flow paths in the air gap and hot air is returned to the cooler
via hot air ducts for re-cooling and drawn again by the fans.

ROTOR WINDING
Construction:
The field winding consists of several series connected coils inserted into
the longitudinal slots of the rotor body. The coils are wound so those two poles
are obtained. The solid conductors have a rectangular cross-section and are
provided with axial slots for radial discharge of the cooling gas. The individual
conductors are bent to obtain half turns. After insertion into the rotor slots, these
turns are combined to form full turns of series connected turns of one slot
constituting one coil. The individual coils of the rotor winding are electrically
series connected so that one north and one south magnetic pole are obtained.

Insulation:
The insulation between the individual turns is made of layers of glass fiber
laminate. The coils are insulated from the rotor body with L shaped strips of glass
fiber laminate with Nomex interlinear. The strips are provided with axial slot of the
same cross- section and spacing as used on the rotor windings.

Rotor Slot Wedges:

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 an
alloy of high strength and good electrical conductivity, and are also used as
damper wedged bars. The retaining rings act as short circuit rings to induced
currents in the damper windings.

ROTOR RETAINING RING:

The rotor retaining rings with stand the centrifugal forces
due to the end windings one end of each ring is shrunk on the
r o t o r b o d y, w h i l e t h e o t h e r e n d o f t h e r i n g o v e r h a n g s t h e e n d
windings without contact on the shaft. The shrunk on hub at the
free end of the retaining ring serves to reinforce the retaining
ring and secures the end winding in the axial director at the
same time. The shrink seat of the retaining ring is silvered
plated, ensuring a low contact resistance for induced current.
To r e d u c e t h e s t r a y l o s s e s a n d h a v e h i g h s t r e n g t h , t h e r i n g s
are made of non-magnetic, cold worked materials.

FIELD CONNECTIONS:
The field connections provide the electrical connection between the rotor
winding and the exciter.
Terminal Lug:
Consists of a copper conductor of rectangular cross-section. One end of
the terminal lug is brazed to the rotor winding, while the other end is screwed to
the radial bolt.
Radial Bolt:
The field current lead located in the shaft bore is connected to the terminal
lug through a radial bolt. The radial bolt is made from steel and screwed into the
field current lead in the shaft bore.
ROTOR FAN:
The generator cooling air circulated by two axial flow fans located on the rotor
shaft one at either 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 ports
along the rotor. The blades of the fan have threaded roots for being screwed into the rotor
shaft. The blades are forged from an aluminum alloy. Threaded root fastening permits the
blade angle to be changed. TEST PROCEDURES
Mechanical run and measurement of vibrations at rated speed: This test is run
after assembly of machine on test bed.

Equipment for running test:

D.C motor drives system.
Bearing lubricating system
Cooling water system.
Current transformers - 2 nos.
Potential transformers - 2nos.
D.C current shunts - 2 nos.
A.C volt meters - 3nos.
DC millivolt meters - 2 nos.
Phase sequence indicator.
Multi meter for continuity checks.
Vibration monitor.
RTDs temperature monitor.
50 Hz A.C High voltage test equipment.
Meggers
Micro ohm meter.
Connecting leads and earthing cables.
The turbo-generator under test is assembled separately with out coolers and
enclosures (if any), on a test foundation frame using it's own bearings and
coupled to a calibrated D.C. drive motor with gearbox of suitable capacity (1900
kw /1300/290 kw). The generators, which have brush less excitation system, are
tested with additional test pit slip rind shaft. The power to the drive motor and the
field of the generator are drawn independently from the Thyristor connectors /
Ward - Leonard sets situated in electrical machine rooms and controlled from test
gallery.
The machine is rolled and run at rated speed after ensuring the bearing oil, and
kept at rated speed for stabilization of bearing temperatures. The vibrations are
measured at rated speed on both the bearings housings (pedestals) in

Horizontal, vertical and Axial directions with the help of vibrating meters which is
internally connected to the monitor and the vibrations are noted in the form of
graphs. The temperature of stator is monitored by RTDs / Thermocouples
embedded in winding, core and tooth.
Measurement of mechanical losses, short circuit characteristic and losses:
The machine is prepared for short circuit characteristics using current
transformers and shorting links. The machine is run at rated speed and drive
motor input voltage and current are noted and m/c is excited gradually in steps,
at 20%, 30%, 40%, 50%. At each step the following parameters are noted.
Stator current (Ia and Ib)
Rotor current corresponding to stator current (If).
Drive motor voltage and current corresponding to stator current (V d & Id)
Bearing vibrations at rated stator current.
RTD readings at rated stator current.
The excitation is reduced and cut off. The speed is reduced and the machine is
cooled at lower speed. The temperatures are checked from RTDs. The machine
is stopped when it is sufficiently cooled down.
From above data, the characteristic curves are plotted as follows % In v/s If.
% In v/s m/c losses in kw. (Fig 6 sample of m/c losses curves) xerox 11
output
% Efficiency of TG

. 100
output +total losses

Field current at 100% En from OCC

S.C.R

=
Field current at 100% In from SCC

Measurement of mechanical losses, open circuit characteristic and losses.

The machine is prepared for open circuit characteristic.
The

machine is run at rated speed and drive motor in put voltage

current

are

noted

and

m/c

is

excited

gradually

in

steps,

and
at

20%,30%,40%,50%,60%,80%,95%,100%,105%,110%,115%,120%,125%130
%
At each step the following parameters are noted.
1. Stator voltages (Vab,Vbc, & Vca)
2. Rotor current corresponding to stator voltage (If)
3. Drive motor voltage and current corresponding to stator voltage. (V c & Id)
At 95% En following parameters are noted.
4. Shaft voltage.
5. Checking of phase sequence.
6. Bearing vibrations at rated stator voltage.
7. RTD readings at rated stator voltage.
The excitation is reduced and cut off. The speed is reduced and the machine is
cooled at lower speed. The temperatures are checked from m/c RTDs. The m/c
is stopped when it is sufficiently cooled down.
From the above data, characteristic curves are plotted as follows % En v/s If.
% En v/s m/c losses in kw.
Measurement of Shaft voltage:

Shaft voltage of generator is measured using multimeter or a high input

impedance a.c voltmeter across the two ends of the rotor when machine is in
O.C. condition at 100%
Checking of Phase sequence:
Phase sequence of generator is checked using a phase sequence indicator
across PT output terminals when m/c is in OC. Condition at 100%.
Measurement of rotor impedance.
Equipment
50 Hz (Power frequency) A.C source.
A.C.Voltmeter.
A.C.Ammeter
Multimeter for continuity checks.
Current trasformer (50 / 5A OR 100 / 5A)
Connecting leads.
Rotor impedance is measured at standstill and at rated speed of the machine.
Evaluation of Impedance:
V
Z
Where

I
Impedance in ohm

Voltage in Volts.

Current in Amps.

Measurement of insulation resistances of rotor windings before and after high

voltage test.
Equipment:

Motorized Megger (1000 V/ 2500 V)

Earthing Rod & earthing cable.
Insulation resistance of the rotor windings are measured before and after high
voltage test using Megger of 1000 V for rotor windings. The values are taken at
15 sec. And at 60 sec. A absorption coefficient of insulation is found out as ,
IR at 60 "
Absorption coefficient

=
IR at 15 "

This value for H.V. test should be 1.5

The winding is discharged to earth after each measurement.
High voltage test on rotor windings
50 Hz A.C High Voltage transformer and its Induction Regulator / Input
autotransformer.
Potential transformer
Volt meter
Binding wire.
Earthing rod & earthing cable.
The m/c is prepared for High voltage test. When high voltage test is done on one
phase, all other phases and rotor winding, instrumentation cables are earthed.
The high voltage is applied to winding by increasing gradually to required value
and maintained for one minute and reduced gradually to minimum. The
transformer is switched off and winding is discharged to earth. The test is
conducted on all the phases and rotor winding separately.
High voltage levels:

Rotor winding: (10.up) volts.

With minimum of 1500v and maximum of 3500v.
Where, Up = Excitation voltage.
Measurement of DC resistance of rotor windings in cold condition:
Equipment's:
Digital micro ohmmeter and it's measuring leads.
Thermometer.
DC resistances of rotor windings are measured separately using micro
ohmmeter.
Evaluation of resistances at 200 C is done by using formula:
Rt . (235+20)
m

R20 =
(235+T)
where,
R20 = Resistance at 200 C in m

T = average temperature of the rotor winding in

Rt = measured resistance of winding in m

Measurement of D.C. resistances and insulation resistance of RTDs and /or
thermocouples:
The D.C. resistances and insulation resistances of RTDs / thermocouples are
measured using multimeter and megger respectively and noted.

EXCITER
Design Features :
The exciter consists of
Rectifier wheels
Three-phase main exciter
Three-phase pilot exciter
The three-phase pilot exciter has a revolving field with permanent-magnet
poles. The three-phase ac is fed to the field of the revolving-armature main
exciter via a stationary regulator and rectifier unit. The three phase ac induced in
the rotor of the main exciter is rectified by the rotating rectifier bridge and fed to
the field winding of the generator rotor through the dc lead in the rotor shaft.
A common shaft carries the rectifier wheels, the rotor of the main exciter
and the permanent-magnet rotor of the pilot exciter. The generator and exciter
rotors are thus supported on a total of three bearings. Mechanical coupling of the
two shaft assemblies results in coupling of the dc leads in the central shaft bore
through the Multi contact electrical contact system.
Rectifier Wheels:
The main components of the rectifier wheels are the silicon diodes, which
are arranged in the rectifier wheels in a three-phase bridge circuit. A plate spring
assembly produces the contact pressure for the silicon wafer of the diodes. One
diode each is mounted in each light metal heat sink and then connected in
parallel. Associated with each diode is a fuse, which serves to switch off the
diode from the circuit if it fails. Each arm of the diode bridge is provided with one
R.C.block. The three-phase connection between armature and diodes is obtained
via copper conductors arranged on the shaft circumference between the rectifier

wheels and the main exciter. One conductor is provided for each arm of Diode
Bridge. The conductors originate at a bus ring system of the main exciter.
Three-phase Pilot Exciter:
The three-phase pilot exciter has a frame, which accommodates the
laminated core with the three-phase winding. The rotor consists of a hub with
mounted poles. Each pole consists of separate permanent magnets, which are
housed, in a non-magnetic metallic enclosure.
Three-phase Main Exciter:
The three-phase main exciter is a six revolving armature unit, the frame
poles with the field and damper winding. The field winding is arranged on the
laminated magnetic poles. The rotor consists of stacked laminations, which are
compressed by through bolts over compression rings. The three-phase winding
is inserted in the slots of the laminated rotor. The winding conductors are
transposed within the core length and the end turns of the winding are secured
with steel bands. The winding ends are run to a bus ring system to which the
three-phase leads leading to the rectifier wheels are also connected. After full
impregnation with epoxy resin and curing, the complete rotor is shrunk onto the
shaft.
* Using a DC generator we have a problem of connections at high speeds
like 3000 rpm, which is usually reduced to 1000 rpm with the help of gearbox. It
is difficult to obtain commutation at this speed without sparks. In order to avoid
this various brush less exciter is used whose circuit diagram is as follows:
The generator rotor is supported at two journal bearings. The bearings
consist of a bearing pedestal and bearing shell is split into two halves to facilitate
assembly. The bearing pedestals are iron castings and the bearing shells are
steel castings. The bearing pedestal is provided with a spherical seating surface
and the bearing shell rests in it with its outer spherical surface. The inner surface
of bearing shell is provided with spiral grooves and cast with Babbitt metal.

Bearing Oil Supply:

The oil required for bearing lubrication and cooling is
obtained from the turbine oil supply system and supplied to the
lubricating groove in the bottom-bearing sleeve. The upper
bearing sleeve consists of a wide over flow groove through
which oil is distributed over the shaft journal and fed to the
lubricating gap.
Bearing Temperatures:
The temperatures of each bearing are monitored by one double-element
RTD. The RTD is screwed in position on side of the lower bearing sleeve from
outside with the detector extending to the Babbitt liner.

Exciters
Test conducted in exciters
Mechanical run and measurement of vibrations at rated speed.
The machine is run to rated rpm after ensuring the bearing oil and kept at rated
speed for stabilisation of bearing temperatures. The vibrations are measured on
both the bearing housing (pedestals) using vibration probes and vibration
monitors in horizontal, vertical and axial directions. Drive motor input voltage and
current are measured to evaluate losses.
Open circuit characteristic:
The machine is prepared for open circuit characteristic and a

500 resistance

is connected across the slip rings. This is to allow a minimum current to pass
through the diodes for voltage measurement. The machine is run at rated speed
and field is excited gradually in suitable steps upto rated output voltage.
At each step following parameters are noted:
Va : out put voltage of exciter.
If : field current of the exciter.
Vq1,Vq2 : quadrature axis coil voltages, and
Vd : Drive motor voltage.

Id : drive motor current. and bearing vibrations.

Load magnetization characteristics and calibration of quadratic axis coils:
The machine is prepared for load magnetization characteristics. A variable water
load resistance is connected across the slip rings.
The machine is run at rated speed, load breaker is closed and m/c is excited
gradually. The following parameters are noted down in steps up to the rated
current by adjusting load resistance to R40. The load resistance is maintained at
R40 at all the steps by the adjusting the water load resistance.
Measurement of DC Resistances of armature windings, main pole winding
and quadrature axis coils:
After dynamic tests the machine is allowed for cooling and when it is sufficiently
cooled, the DC resistances of all the three armature windings, main pole winding
and quadrature axis coil are measured separately by micro ohm meter. The
ambient temperature is also recorded and evaluation of resistances at 20 0 C is
done by using the formula:
Rt . (235 +20)
R20 =

------------------
( 235+t)

R20 = D.C. resistance at 200 C

T = temperature of the winding in 0 C
Rt = DC resistance of the winding at 0 C
Measurement of IR value and high voltage tests:
Before performing these tests, all the diodes are shorted by the copper wire. This
is to protect the diodes during meggering and HV tests on armature winding.
Rotor and stator bodies are properly earthed. IR values of the windings are

measured with 500 or 1000 volts megger and values at 15" and 69" are noted
before and after High voltage tests.
HV test is done on individual windings using high voltage test kit by regulating
primary voltage to transformer. Slowly HV is reached and maintained for one
minute and reduced to zero. The object is then discharged by earth rod and IR
values are taken. When test is done on one winding, the other windings are
earthed.
Testing of permanent magnet generator
The PMG is assembled along with Brush less Exciter on the test foundation
frame. The output is connected to a three-phase resistance load (variable in
steps). As PMG has got permanently magnetised field poles, it starts generating
voltage right from start of mechanical run.

TESTING OF TURBO GENERATORS

The various tests conducted on Turbo Generators are as follows:
1.

Air leak test & determination of leakage per day.

2.

Mechanical run test in air medium.

3.

Bearing vibration measurements.

4.

Over hang winding and core vibration measurement at 2850, 3000 & 3150
rpm.

5.

Mechanical heat run test at rated speed (i.e. 3000 rpm) to determine the
heat up as a result of Mechanical losses in Hydrogen medium.

6.

Noise level measurement with meter dB(A) at 3000 rpm.

7.

Three phase short circuit characteristic and losses measurement up to

110% In i.e. 11679.8A in steps at 20%, 40%, 60%, 80%, 100% and 110%
In.

8.

IR value measurement of stator windings after S C C heat run test.

9.

Open circuit characteristic and losses measurement up to 120% E n i.e.

12.6 KV in steps at 20%, 40%, 60%, 80%, 90%, 95%, 100%, 105%, 110%
& 120% En.

10.

Shaft voltage measurement at 100% En.

11.

Phase sequence and voltage balance checks.

12.

Impedance measurement of rotor with 50Hz supply.

13.

IR value measurement of the stator and rotor windings

after hydrogen purging out.

14.

Impedance measurement of Rotor at stand still, 1000, 2000 & 3000 rpm
by 50 Hz ac supply at 5A, 10A (Voltage limited to generator terminals open
circuited in air medium).

15.

Impedance measurement of Rotor at stand still, 1000, 2000 & 3000 rpm
by 50 Hz ac supply at 5A, 10A (Voltage limited to 250v) generator
terminals short-circuited in air medium.

16.

IR value measurement and high voltage (level : 1000 v) on

Rotor winding at 3000 rpm.

Testing of Turbo Generators

T h e a r e d i f f e r e n t t yp e s o f T E S T S a r e :
1. EXAMINATION OF THE ROTOR FORGINGS.
2. ROTOR COIL BINDING RING TEST.
3. HYDRAULIC TEST ON THE STATOR CASING.
4. CORE FLUX TEST.
5. ROTOR WINDING AND CELL INSULATION TESTS.
6. TESTS ON THE STATOR COIL.
7. BALANCING AND OVER SPEEDING OF THE ROTORS.

LET US DISCUSS BRIEFLY ABOUT ALL THESE TESTS,

1. EXAMINATION OF THE ROTOR FORGINGS
T H E R O T O R , B E I N G T H E M O S T H I G H LY S T R E S T E D
PAR T

OF

THE

TURBO

G E N E R ATO R ,

MUST

BE

PROVED

T H R O U G H LY S O U N D B E F O R E I T I S PAS S E D I N T O S E R V I C E .
IT

IS

SUBJECTED

TO A LARGE

NUMBER

OF

RIGOROUS

D Y N A M I C P H Y S I C A L , O P T I C A L AN D E L E T R I C A L I N S P E C T I O N
T E S T S . T H E S E T E S T S AR E D E S I G N E D T O D E T E C T L I K E LY
F L AW S I N T H E N M ATE R I A L , AS E A R LY AS P O S S I B L E .

INTIAL

tests are done at forging manufactures works.

SPECIMEN PIECES ARE OUT FROM THE SHAFT AND ROTOR BODY
AND SUBJECTED TO

(A) TENSILE

(B) BENDING

(C) PREMEABILITY

TESTS TO CHECK ITS CONFORMITY WITH THE SPECIFICATION.

SULPHUR PRINTS ARE TAKEN AT SHAFT END AND ON ROTOR
BODY FOR MICROSCOPIC EXAMINATION TO STUDY THE PRESENCE OF
SULPHIDE.
A SURFACE INSPECTION IS MADE AAFTER ROUGH MACHINING AT
STEEL MAKERS WORKS.
M A G N E T I C T E S T S AR E C O N D U C T E D T O D I S C L O S E
ANY

HAIR

CRACKS

NOT

V I S U A L LY

D E T E C TAB L E .

THE

PROCESS consists of magnetizing the forging and exposing the

surface under examination to a stream of paraffin carrying
m a g n e t i c a l l y p r e p a r e d f i n e l y d i v i d e d i r o n p o w d e r. F i n e c r a c k s
are disclosed by a concentration of iron particles bridging the
cracks under the influence of the magnetic field.
The rotor forging is bored along its axis and magnetic
crack detection test carried out .the core of a rotor forging is
trepanned and rough machined stage these tests detect sub
surface unsoundness, cracks or non metallic inclusions.
The services of specialist staff in metals section of Research
and development division of H.E .are utilized for all the abovementioned tests.
ROTOR COIL BINDING RING TESTS :
T h e s e a r e t h e m o s t h i g h l y s t r e s s e d p a r t s o f t h e r o t o r, m a d e
of non magnetic austenitic steel forging and warm worked by a
s p e c i a l p r o c e s s c a l l e d m a n d r e l E x p a n d i n g . To a v o i d l o c a l
concentration of high stresses, ventilating or locating purposes.
Specimen taken from ends of forging are subjected to
tensile and bending tests.
Crack detection: Magnetic crack detection technique is not
effective because of the non-magnetic materials of rings .the
m e t h o d a d o p t e d i s d ye - p e n e t r a t i n g t e s t s . T h e s u r f a c e s t o b e
e x a m i n e d a r e m a c h i n e d t o a s m o o t h f i n i s h a n d a r e s p r a ye d w i t h
a f i n e w h i t e p o w d e r, s u c h a s F r e n c h c h a l k . T h e d ye w i l l a p p e a r
on the chalk as clearly visible red lines against the white
background if cracks are present.
H Y D R A U L I C T E S T S : R i n g s a r e s u b j e c t e d t o h yd r a u l i c t e s t s w i t h
oil under pressure, which induces stresses up to 65% of the
yield point.

H yd r a u l i c t e s t o n s t a t o r c a s i n g :

the purpose of this tests is to

ensure that the frame is sound top the extent of withstanding

the pressure associated with explosion of a mixture of air in
h yd r o g e n a t e d a l s o t o c h e c k t h a t a l l t h e w e l d s a r e s o u n d a n d
free from leakage cracks .the test pressure of water for all
h yd r o g e n c o o l e d s t a t o r s i s 7 0 l b s / i n c h 2 i r r e s p e c t i v e o f c a s i n g
h yd r o g e n

design

pressure.

Every

h o u r,

for

six

hours,

the

pressure is first increased to maximum value and then reduced

t o z e r o s u d d e n l y, t h e r e b y g i v i n g p r e s s u r e i m p a c t s .

S t a t o r c o r e F l u x Test : I m m e d i a t e l y a f t e r t h e c o r e i s b u i l t
up and before it is wound, a test is made to detect the
presence

of

local

hot

spot.

Whenever

there

are

shorts

between adjacent core lamination s, due to break of inter

laminar insulation or burrs on the edges, high eddy currents
flow giving rise to temperature rise in that zone. Several turns
of cable are wound through the machine bore and out side
frame. The winding is fed from a single-phase variable voltage
5 0 c yc l e s s u p p l y. T h e o b j e c t i s t o s e t u p i n t h e c o r e , t h e f u l l
working flux corresponding to rated voltage of the machine.
Bad

local

heating

is

caused

by

shorted

and

burred

core

laminations and may be detected after a short time by running

the hand over the surface of the core. A set of reading on core
thermocouples

is

also

taken

as

well

as

external

contact

thermometers are used to take temperature at other points of

yoke and core. The remedy for such defects is to introduce
further insulation between laminations and in all, but the worst
cases;

this

may

be

done

with

out

dismantling

the

core.

Wattmeter connected to the input indicates the iron loss and by

k e e p i n g c o m p r e h e n s i v e r e c o r d s f o r e v e r y s i z e a n d t yp e o f

machine, the readings obtained may be used to estimate the

stator core loss in service.

By intelligent analysis of the

results a bad core with perhaps an excessive iron loss may be

detected and remedied before it is wound.
ROTOR

W I N D I N G AN D C E L L T E S T S B E F O R E AS S E M B LY :

The rotor coils and their insulation are subjected to high

stress when in normal operation. Thus a through inspection of
these is necessary before putting them in the rotor slots as
otherwise any replacement of the faulty insulation or cell would
necessitate removing the coil binding rings and wedges, which
is cumbersome job.

The rotor winding is subjected to a final

shipping pressure test of 3.5 kV for one minute in case of 30

Mv and 120MW.
TESTS ON ROTOR SLOT CELLS : The epoxy impregnated glass
cell forms ground insulation and for H.E.rotors, a voltage test
of

10

KV

for

one

minute

is

applied

in

the

initial

stage.

Subsequent to the testing of the cell during various stages of

assemble at reduced, the entire winding is finally subjected to
a shipping test voltage of 3500 volts.

TESTS ON ROTOR COILS:

TESTS ON ROTOR COILS:
Tes t B e t w e e n t u r n s : T h e r o t o r c o i l s e c t i o n s a r e m a d e u p o f
a number of turns which are formed in halves and then
assembled with their inter turn insulation and bonded with
a n a d h e s i v e i n t h e s t e a m h e a t e d p r e s s . Al t h o u g h n o r m a l
working voltage per turn may be very small, a turn-to-turn
test of 240volts is done to exercise quality control.
TOP TURN TROUGH : The insulation at top and bottom of
the

rotor

distance

slot

provides

between

adequate

copper

and

and

rotor

safe

steel,

creep
in

case

age
of

slotted copper 500 volts for one minute is applied for one
minute to test the top through.
Tes t O n C o m p l e t e R o t o r W i n d i n g : Af t e r p l a c i n g t h e c o i l i n
the slots, before joining after jointing, fitting dampers and
wedges and fitting coil binding rings connected to the
collector rings up to run at speed, the graded high voltage
tests are carried out at each stage, starting with down to
shipping pressure test after over speed run. Shipping test
on rotor is both in standstill and running condition.
COLLECTOR LEADS: A high voltage equivalent to the
shipping test plus 1500 volts is applied to collector leads
when fitted in bore with studs of seals fitted but before
connecting to windings.
T E S T S O N S TATO R C O I L S : As p e r t h e s t a n d a r d s , t h e
stator winding has to be subjected to shipping pressure
test of (2 line volts +1KV). Incase of 30Mw and 120MW

g e n e r a t o r. I n o r d e r t h a t m a c h i n e w h e n w o u n d w i t h s t a n d s
this final voltage test, and any faulty coil is eliminated
during the various stages of coil manufacture and winding.
Because the continued application of high voltage tests
may over stress the winding insulation, the voltage is
reduced at various stages.

Test between parallel straps :

This is a test of strap

i n s u l a t i o n p r o v i d e d f o r e d d y E . M . F., a l o w v o l t a g e o f t h e
order of 350 volts for 3seconds is applied.
COILS

IN

M A N U FAC T U R E

AN D

WINDING

SECTIONS :

When the coils are first tested, a voltage of 8 K V in

excess

of

shipping

pressure

test

is

applied

and

this

voltage tests are repeated.

TESTS ON THERMOCOUPLES :

1 0 0 0 Vol t s m e g g e r t e s t i s

applied to the thermocouples.

B AL AN C I N G AN D O V E R S P E E D I N G O F R O T O R S :
BALANCING:
testing

is

one of the most important preliminaries to

that

of

balancing

the

rotors.

Before

over

s p e e d i n g , t h e r o t o r i s d yn a m i c a l l y b a l a n c e d , i n c o l d a s
well as hot conditions. A set of run up and run down
curves is taken sure those critical speeds of vibration
amplitudes. The design makes sure that the critical speed
is well away from the running speed.
OVERSPEEDING:

In order to check the soundness of all

p a r t s a n d f i t t i n g o n r o t o r a s s e m b l y, t h e r o t o r i s r u n a t a n
over speeding test house at Bhopal is one of the most
modern in the world.

Performance Tests
WORKS TESTS ON COMPLETED MECHINE:
There are two types of tests they are :
Routine tests
Type test.
ROUTINE TESTS ON TURBOGENERATOR
1.0.0

Scope:

This test procedure covers procedures for Routine Tests on

2.0.0

Turbo generators.
Tests conducted:
1. Mechanical run and measurement of vibrations at rated speed.
2. Measurement of mechanical losses, short circuit characteristic and
losses.
3. Measurement of mechanical losses, open circuit characteristic and
losses.
4. Measurement of shaft voltage.
5. Checking of phase sequence.
6. Measurement of Rotor Impedance (rotor inside stator).
7. Measurement of insulation resistance of stator & rotor windings before
and after high voltage test (m/c at rest).
8. High Voltage test on stator and rotor windings (m/c at rest).
9. Measurement of Polarization Index of stator winding.
10. Measurement of d.c. Resistance of stator & rotor windings in cold
condition.
11. Measurement of d.c. Resistance and insulation resistance of RTDs.

1.0.0

TYPE TESTS ON TURBOGENERATORS

Scope: This test procedure covers procedures for Type Tests on
Turbo generators.

2.0.0

Tests conducted
1. Measurement of Capacitance of stator winding.
2. Measurement of Tan of sample coils of stator winding
impregnated along with stator.
3. Heat run tests:
a) Mechanical heat run test.
b) Short circuit heat run test.
c) Open circuit heat run test.
4. Voltage waveform analysis and determination of Telephone
harmonic factor (THF).
5. Measurement of residual voltage of stator windings at rated
speed.
6. Line to Line sustained short circuit test and determination of
Negative sequence reactance (X2).
7. Line to Line and to Neutral sustained short circuit test and
determination of Zero sequence reactance (Xo).
8. Retardation test for determination of GD2.
9. Three phase sudden short circuit test at 30%En and
determination of reactances and time constants.

1. Circuit Dry out Insulation resistance of rotor and stator

2. Resistance of machine winding.
3. Phase sequence test.
4 . H yd r o g e n L e a k a g e t e s t s .
5. Zero Excitation rated speed run
6. Open characteristic curve and losses.
7. Short-circuit characteristic curve and losses.
8. Zero power factor curve point and wattles temperature test.
9. Waveform and harmonic analysis of voltage waveform.
10. Negative sequence and zero sequence reactance.
11. S u d d e n s h o r t c i r c u i t a n d o s c i l l o g r a m s .
12. Shipping

pressure test.

WORK TEST ON COMPLETED MACHINE PERFORMANCE

TESTS:
The machine is assembled and erected at the heavy rotating
plant test bay for test.
D R Y O U T I N S U L ATI O N R E S I S T E D O F R O T O R AN D S TATO R
WINDINGS:
Before starting with running tests, the stator windings are dried
out by circulating current in the windings from an external dc
source.

Input

temperature

of

of

power

the

end

is

so

controlled

windings

to

as

to

maximum

limit
of

the

80cby

thermometer.
Progress of dry out is observed by one minute insulation
r e s i s t a n c e r e a d i n g w i t h 1 0 0 0 v o l t s M u g g e r. W i t h t h e a p p l i c a t i o n
of heat, the insulation resistance will initially drop and then will
rise

again

over

period

of

time

and

finally

becomes

approximately constant at constant temperature. Ratio of ten

minute reading i.e. polarization index, when more than 2 gives
an indication of good dry out. Insulation resistance reading of
each

phase,

with

others

grounded

is

recorded.

Similarly

insulation resistance readings of rotor winding to ground are

taken.

R E S I S TAN C E O F MA C H I N E W I N D I N G S :
Measurement of cold winding resistance's, both for stator and
rotor must be very accurate since it forms the basis of (a)
calculating copper under cold and hot conditions, and (b) for
determining

the

rise

in

temperature

of

rotor

winding

by

r e s i s t a n c e m e t h o d a t t h e e n d o f t h e t e m p e r a t u r e t e s t . Al l
precautions are taken to as certain correct temperature of the
winding while measuring cold resistance. Since the winding

resistance of turbo generator is quite low; a modified form of

w h e t s t o n e b r i d g e i . e . K e l v i n s d o u b l e b r i d g e i s e m p l o ye d f o r
m e a s u r e m e n t . t h e d o u b l e b r i d g e i s e m p l o ye d f o r m e a s u r e m e n t .
The bridge does away with the necessity of accounting for the
resistance of loads. Resistance between phases for stator and
between slip rings for is recorded along with the cold winding
temperature at the time of measurement.

For calculating resistance at any other temperature t2 the

following formula is used:
FORMULA WRITE
K= constant for copper=234.5

PHASE SEQUENCE TEST: The phase sequence test is to check

the agreement of the terminal markings that have been
s p e c i f i e d . P h a s e s e q u e n c e i n d i c a t o r.
H YDROGEN LEAKAGE TEST : Before adm itting hydrogen into
the casing, it must be made sure that machine is gas tight and
explosion proof. Its subjected to a pneumatic test or 3.16
kg/cm2.larger leaks are detected by using soap water solution
and soon as these are remedied, air supply is cut off to old the
pressure in the casing over 24 hours. From initial and final
pressure as well as temperature reading, the amount of leakage
can be calculated.

Z E R O E X I TATI O N R ATE D S P E E D R U N : A t r i a l r u n i s m a d e o n
the turbo generator to check state of balance and to ensure
that the bearings are run in and that bearing oil temperature is
reasofromthe nably constant. A synchronous driving motor
through speed increasing gears drives the machine. The
calibration curve of driving motor with gear is established prior
to stator of tests. The machine is brought to rated speed of
3000rpm with no excitation and input readings on the driving
m o t o r r e c o r d e d b y w a t t m e t e r m e t h o d w h e n c o n d i t i o n s s t e a d y.
From the result of above test after deducting derived motor and
gear losses, friction and windage losses of the machine under
test are computed. These losses are for rated speed. Bearing
oil quantities with inlet temperatures of oil can yield
calculations for bearing loss. From a previous data on seal face
losses determined from a prototype test, the total friction loss
in bearing and seals can be established. The windage loss is
computed for design office use by the difference. Since bearing
loss goes to oil, any heat carried out on the unexcited machine
will give temperature rise due to windage.

LET US DISCUS BRIEFLY ABOUT ALL THESE TESTS,

1.: EXAMINATION OF THE ROTOR FORGINGS

T h e r o t o r, b e i n g t h e m o s t h i g h l y s t r e s s e d p a r t o f t h e
t u r b o g e n e r a t o r, m u s t b e p r o v e d t h o r o u g h l y s o u n d b e f o r e i t i s
passed into service. It is subjected to a large number of
rigorous dynamic physical, optical and electrical inspection
tests. These tests are designed to detect likely fl aws in the
material, as early as possible.
forging manufactures works.

Initial tests are done at

Specimen pieces are out from the shaft and rotor body and subjected
to (a) tensile (b) bending (c) permeability tests to check its conformity with
the specification.
Sculpture prints are taken at shaft end and on rotor body for
microscopic examination to study the presence of supplied.
A surface inspection is made after rough machining at steel makers
works.
Magnetic tests are conducted to disclose any hair
cracks

not

magnetizing

visually
the

detectable

forging

and

.The

process

exposing

the

consists

surface

of

under

examination to a stream of paraffin carrying magnetically

prepared

finely

divided

iron

p o w d e r.

Fine

cracks

are

disclosed by a concentration of iron particles bridging the

cracks under the influence of the magnetic field.
The rotor forging is bored along its exits and magnetic
crack detection test carried out .the core of a rotor forging is
trepanned and rough machined stage these tests detect sub
surface unsoundness, cracks or non metallic inclusions.
The services of specialist staff in metals section of Research
and development division of H.E .are utilized for all the
above-mentioned tests.
ROTOR COIL BINDING RING TESTS :
T h e s e a r e t h e m o s t h i g h l y s t r e s s e d p a r t s o f t h e r o t o r,
made of non magnetic austenitic steel forging and warm
w o r k e d b y a s p e c i a l p r o c e s s c a l l e d m a n d r e l E x p a n d i n g . To
avoid local concentration of high stresses, ventilating or
locating purposes.

Specimen taken from ends of forging are subjected to

tensile and bending tests.
Crack detection: Magnetic

crack detection technique is not

effective because of the non-magnetic materials of rings .the

m ethod adopted is dye-penetrating tests. The surfaces to be
examined are machined to a smooth finish and are sprayed
w i t h a f i n e w h i t e p o w d e r, s u c h a s F r e n c h c h a l k . T h e d y e w i l l
appear on the chalk as clearly visible red lines against the
white background if cracks are present.
HYDRAULIC TESTS : Rings are subjected to hydraulic tests
with oil under pressure, which induces stresses up to 65% of
the yield point.
Hydraulic test on stator casing:

the purpose of this tests is

to

sound

ensure

that

the

frame

is

top

the

extent

of

withstanding the pressure associated with explosion of a

mixture of air in hydrogenated also to check that all the welds
are sound and free from leakage cracks .the test pressure of
water for all

hydrogen cooled stators is 70 l bs /inch2

i r r e s p e c t i v e o f c a s i n g h y d r o g e n d e s i g n p r e s s u r e . E v e r y h o u r,
for six hours, the pressure is first increased to maximum
v a l u e a n d t h e n r e d u c e d t o z e r o s u d d e n l y, t h e r e b y g i v i n g
pressure impacts.

Stator core Flux Test : Immediately

after

the core

is built up and before it is wound, a test is made to detect

t h e p r e s e n c e o f l o c a l h o t s p o t . W h e n e ve r t h e r e a r e s h o r t s
between adjacent core lamination s, due to break of inter

laminar insulation or burrs on the edges, high eddy currents

flow giving rise to temperature rise in that zone. Several
turns of cable are wound through the machine bore and out
side frame. The winding is fed from a single-phase variable
v o l t a g e 5 0 c y c l e s s u p p l y. T h e o b j e c t i s t o s e t u p i n t h e c o r e ,
the full working flux corresponding to rated voltage of the
machine. Bad local heating is caused by shorted and burred
core laminations and may be detected after a short time by
running the hand over the surface of the core.

A set of

reading on core thermocouples is also taken as well as

external contact thermometers are used to take temperature
at other points of yoke and core. The remedy for such
defects

are

to

introduce

further

insulation

between

laminations and in all, but the worst cases; this may be done
w i t h o u t d i s m a n t l i n g t h e c o r e . W at t m e t e r c o n n e c t e d t o t h e
input indicates the iron loss and by keeping comprehensive
records for every size and type of machine, the readings
obtained may be used to estimate the stator core loss in
service. By intelligent analysis of the results a bad core with
perhaps

an

excessive

iron

loss

may

be

detected

and

remedied before it is wound.

R O T O R W I N D I N G AN D C E L L T E S T S B E F O R E AS S E M B LY :
The rotor coils and their insulation are subjected to high
stress when in normal operation. Thus a through inspection
of these is necessary before putting them in the rotor slots
as otherwise any replacement of the faulty insulation or cell
would

necessitate

removing

the

coil

wedges, which is cumbersome job.

binding

rings

and

The rotor winding is

subjected to a final shipping pressure test of 3.5 kV for one

m inute in case of 30 MW and 120MW.

TESTS ON ROTOR SLOT CELLS : The epoxy im pregnated

glass cell forms ground insulation and for H.E.rotors, a
voltage test of 10 KV for one minute is applied in the initial
stage. Subsequent to the testing of the cell during various
stages of assemble at reduced, the entire winding is finally
subjected to a shipping test voltage of 3500 volts.

T E S T S O N R O TOR C O I L S :
TESTS ON ROTOR COILS :
Tes t B e t w e e n t u r n s : T h e r o t o r c o i l s e c t i o n s a r e m a d e u p o f a
number

of

turns

which

are

formed

in

halves

and

then

assembled with their inter turn insulation and bonded with an

a d h e s i v e i n t h e s t e a m h e a t e d p r e s s . Al t h o u g h n o r m a l w o r k i n g
voltage per turn may be very small, a turn-to-turn test of
240volts is done to exercise quality control.
TOP TURN TROUGH : The insulation at top and bottom of the
rotor

slot

provides

adequate

and

safe

creep

age

distance

between copper and rotor steel, in case of slotted copper 500

volts for one minute is applied for one minute to test the top
through.
Tes t O n C o m p l e t e R o t o r W i n d i n g :

Af t e r p l a c i n g t h e c o i l i n t h e

slots, before joining after jointing, fitting dampers and wedges

and fitting coil binding rings connected to the collector rings up
to run at speed, the graded high voltage tests are carried out at
each stage, starting with down to shipping pressure test after
over speed run.

Shipping test on rotor is both in standstill and

running condition.

COLLECTOR

LEADS:

high

voltage

equivalent

to

the

shipping test plus 1500 volts is applied to collector leads

when fitted in bore with studs of seals fitted but before
connecting to windings.
T E S T S O N S TATO R C O I L S : As p e r t h e s t a n d a r d s , t h e s t a t o r
winding has to be subjected to shipping pressure test of (2
l i n e v o l t s + 1 K V ) . I n c a s e o f 3 0 M w a n d 1 2 0 M W g e n e r a t o r. I n
order that machine when wound withstands this final voltage
test, and any faulty coil is eliminated during the various
stages

of

coil

manufacture

and

winding.

Because

the

continued application of high voltage tests may over stress

the winding insulation, the voltage is reduced at various
stages.

Tes t b e t we e n pa ra l l e l s t ra p s : T h i s i s a t e s t o f s t r a p
i n s u l a t i o n p r o v i d e d f o r e d d y E . M . F., a l o w v o l t a g e o f t h e
order of 350 volts for 3seconds is applied.
C O I L S I N M A N U FAC T U R E AN D W I N D I N G S E C T I O N S : W h e n
the coils are first tested, a voltage of 8 K V in excess of
shipping pressure test is applied and this voltage tests are
repeated.
TESTS ON THERMOCOUPLES :
applied to the thermocouples.

1 0 0 0 Vol t s m e g g e r t e s t i s

B A L A N C I N G AN D O V E R S P E E D I N G O F R O T O R S :
BALANCING:

one of the most important preliminaries to

testing is that of balancing the rotors. Before over speeding,

the rotor is dynamically balanced, in cold as well as hot
conditions. A set of run up and run down curves is taken sure
those critical speeds of vibration amplitudes.

The design

makes sure that the critical speed is well away from the
running speed.
OVERSPEEDING:

In order to check the soundness of all

p a r t s a n d f i t t i n g o n r o t o r a s s e m b l y, t h e r o t o r i s r u n a t a n o v e r
speeding test house at Bhopal is one of the most modern in
the world.
I.

OCC:

Calculated
Evaluated

% En
If(A)
If(A)

80

100

110

120

If(A) at 100% In on 3 S.C test =

Full load If(A) at rated p.f. =
S.C ratio =
Resistance at 20C (ohm)=
Stator Winding

Rotor Winding

Calculated
Evaluated
Losses in KW
SC St. Cu
Losses
Calculated
Evaluated

Rotor
Cu.Losses

Iron
Losses

Mech.
Losses

2.
Determination of SCR %Xd and
No load Vn =
Ifo =
Ife =
SCR=
Rated output excitation at 0.8 pf I fn =
Xd =
Xd =
3.

Heat run test

Mech
run

heat O.C Heat run at S.C Heat run

110% En

Stator voltage
Stator current
Rotor field volts
Rt field current
4. Cooling medium : stator pressurised at 3bar Hydrogen
Total windage and Mechanical
O.C heat run at
frictional losses
heat run
110% En
SC losses
Iron losses at 110%
En
Iron losses at 110%
In
Rotor losses
5. Measurement of leakage reactances
Zn =Vn / (1.732 X In )
Z =V /(1.732 X I)
R =P/(3 X I2 )
Xa =(Z2 X R2 )(1/2)
%Xa =(Xa /Zn )X100
%Xp =0.63(%Xa)

S.C heat run

6. Capacitance & tan measurement on stator winding

Arrangement
Volt.
R4
N
R3
S
C4
appld

7.

Capacitance & tan measurement :

Cx =

C4 X R4 (R3+100)
N X (R3 + S)

% tan = ( x R4x C4 x 10-4) x 100

Cx %
tan

8.

Measurement of D.C.resistance of Stator & Rotor Windings :

Winding

Stator

Phase

Resistance (mohm)

R at
20 C

A - A0
B - B0
C - C0

9.
Insulation resistance measurement & high voltage test :
Phase
Phase
Before
After
15
Earthed
High Volt.
High Volt.

60

Here we use a megger which produce 5000 V

10.

Measurement of Ohmic resistance and I.R. values of RTDs.

RTD No.
Ohmic resistance
Insulation
Resistance (Mohm)

11.

High Voltage test on Rotor Winding :

Here we use 1000 V Megger.
Rotor
Shaft
Before
After
Winding
High Volt.
High Volt.

15

60

12.
Impedance of Rotor Winding at Stand still and at different speeds.
Speed (rpm)
V
I
Z
3000
2000
1000
Stand still
Similarly we perform for different frequencies of ac voltage (50-500)Hz.
13.

Short circuit heat run test at 100% In :

Time
Rotor Volt.
Rotor Curr.

Rotor R

14.

Open Circuit characteristic & measurement of losses:

Vuv

Vvw

Vwu

%Vn

Iv

Vd

Id

Losses

The same experiment is carried out both in Air and Hydrogen medium.
15.

Three phase short circuit characteristic and measurement of losses.

Ia

Ib

%In

Ir

Vd

Id

Losses

PREPARATION FOR STARTING:

It is prerequisite for start up of the turbo generator that continuous
contacts be maintained between all plant sections directly or indirectly involved in
the starting procedure.
Checking the Transmitters:
Prior to startup, all connections should be rechecked. This applies to
piping as well as to cabling. When checking the cabling, special attention should
be paid to testing the metering and signal cables. All alarm systems should be
checked by changing the setting of the contacts. All temperature measuring
points should also be checked. Unless temperature rises were brought about by
other preparatory work at the measuring points. When doubt exists regarding the
electrical temperature measurements, calibration and line compensation should
be repeated.
Cooling Water Supply:
The coolers should be filled with water on their cooling watersides. To do
this, the cooler vents should be opened.
RUN UP OF GENERATOR:
Start up of generator:
Prior to running the generator oil system should be placed into operation.
The oil flow to the bearings should be checked to ensure an adequate flow. In
addition, drains should be inspected for proper operation.

Run up:
During run up to rated speed, the bearing oil inlet temperature should be
in accordance with the turbine manual. During run up the critical speed ranges
should be passed through quickly and at a uniform rate. Smooth running
depends on several factors. Even minor temperature difference of 1 to 2 dig C
between opposite sides of the rotor may result in rotor distortion, which could
lead to inadmissible vibrations due to unbalance.
Varsity:
To protect the rectifier bridge against over voltages occurring during starting or
during fault conditions, a non-linear resistor is provided. This protective resistor
consists of 6 varistor discs parallel connected between the positive and negative
bus rings.
The varistor discs are clamped between the bush 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.
End shields:
The end of the brushless exciter are closed by endshields. Depending on the
degree of protection of the machine, these endshields have either ventilating
slots or welded-on connection pieces for ventilating ducts.
The endshields on one end is of split construction and has a split sealing ring
screwed to its inner diameter and embracing the sleeve of the rotor hub with little
clearance. The end shield on the other end of the exciter is unplugging.
Ventilation:
The brushless exciter used closed circuit cooling, the air inlet
being on one end and the outlet on other end. The rotor spider
is provided with openings, permitting the passage of cooling air

past

the

rectifier

heat

sinks

and

also

over

the

bus

rings

together with the varistors and the carrier storage-effect circuit.

Maintenance:
The brushless exciter requires only a minimum of maintenance. The machine is
inspected for dust deposits at suitable intervals and are removed when
necessary, usually it is found in the region of heat sinks. A suitable method of
blowing with compressed air is used for this purpose.

MEASURING

DEVICES

AND

SUPERVISORY

EQUIPMENT

INTRODUCTION:
The supervisory equipment, consisting of alarm and measuring devices
gives a visual indication of the system parameters. The supervisory equipments
are regulating systems, automatic control and protective devices, which provides
for a reduction of the manual supervisory work.
T E M P E R ATU R E D E T E C T O R S
Resistance Temperature Detectors (RTDs):
Temperature measurements on the generator are made with RTDs. When
making measurements with RTDs the resistance element is exposed to the
temperature to be measured. The RTD works on principle of the change in
electrical resistance of a conductor due to temperature.
R = Ro(1 + a.T)
Ro= reference resistance at 0C
a = temperature coefficient
T = temperature in C

The temperature coefficient (a) is 3850/deg C, this being the mean value
for the range 0 - 100C.
Rod Type Thermostats :
R o d - t yp e t h e r m o s t a t s a r e u s e d f o r d e t e c t i n g t e m p e r a t u r e
limits. These instruments utilize the different coefficients of
thermal expansion of two dissimilar metals. When exposed to a
temperature rise a rod arranged inside a tube and fitted to one
end of it features a linear expansion different from that of the
s u r r o u n d i n g t u b e . As a r e s u l t o f t h i s a m o v e m e n t i s i n i t i a t e d i n
a switching head at the other end of the detector tube, which in
turn actuates a change over contact. This changeover contact
operates on rising and falling temperature when the set value is
reached. The contacts are connected to the detector tube. The
r o d t yp e t h e r m o s t a t s a r e e m p l o y e d f o r t e m p e r a t u r e d e t e c t i o n i n
pressurized surroundings.
VIBRATION PICKUP
Bearing Housing Vibration Measurement:
The vibration pickup for measurement of the absolute bearing vibration
converts mechanical vibrations into an electrical signal in a seismic type
transducer operating on the permanent magnet plunger coil principle. The
permanent magnet and magnetic flux return path elements are solidly connected
to the sensor casing. The plunger coil is suspended in the sensor casing by
means of a spring.
The maximum velocity of the absolute vibration is measured by means of
the transducer, which is attached to the bearing housing. Vibration in the bearing
housing produce a relative movement between the permanent magnet and the
plunger coil, which induces a voltage in the coil portion to the vibration velocity.
The output signal of the transducers is integrated amplified and then
displayed and recorded as peak-to-peak maximum velocity vibration values.