GENERATOR Mech Construction Original

7/31/2019 GENERATOR Mech Construction Original

1/50

BHEL Hardwar

Turbogenerator-An Introduction
http://g/Documents%20and%20Settings/buzzk/Local%20Settings/Temporary%20Internet%20Files/Local%20Settings/unzipped/0%20Revisions/Corp_Overview_May_2002.ppthttp://g/Documents%20and%20Settings/buzzk/Local%20Settings/Temporary%20Internet%20Files/Local%20Settings/unzipped/0%20Revisions/Corp_Overview_May_2002.ppt


2/50

BHEL Hardwar

Index

1. Historical developments

2. Types of Generator3. Main parts of Turbogenerator & its functions

4. New developments in Turbogeneartors


3/50

BHEL Hardwar

Development of TG

Global development

First single phase generator of 75 KW 1888First 3 phase generator, salient pole 1900First turbo type 3 phase 25 MW generator 1912CEA, UK made 50 HZ as standard frequency for Europe 1925First Hydrogen cooled 3 phase 30 MW generator 1937

First Hydrogen cooled TG with direct cooling of rotor 1949First generator with water cooled stator winding 1956First generator with water cooling for stator and rotor wdg1959


4/50

BHEL Hardwar

Development of TG

In India

THREE PLANTS SET UP:IN 1950s:At Bhopal with British collaboration30 MW & 120 MW Hydrogen Cooled

IN 1960s:At Hardwar with Russian Collaboration100 MW Hydrogen Cooled & 200 MW Hydrogen Cooled

IN 1960s:At Hyderabad with CZECH Collaboration

60 MW Air Cooled & 110 MW Hydrogen Cooled


5/50

BHEL Hardwar

Types of Turbogenerator

Generator Modules :-

Air Cooled Turbogenerator - TARI

Hydrogen Cooled Turbogenerator - THRI

Hydrogen/Water Cooled TG - THDF and THW

Module Nomenclature -

THRI 108/44

THDF 115/59


6/50

BHEL Hardwar

Generator cooling System


7/50

BHEL Hardwar

Stator Slot - TARI / THRI


8/50

BHEL Hardwar

Stator Slot - THDF 500 MW


9/50

BHEL Hardwar

210/235 MW THW Generator


10/50

BHEL Hardwar

Capability of Generator Modules

DESIGN VARIANT GENERATOR MODULE OUTPUT RANGE

TARI 93/38 75-92 MWAIR COOLED TARI 108/36 100-120 MW

TARI 108/41 120-140 MWTARI 108/46 140-170 MWTHRI 93/38 120-150 MWTHRI 108/39 210 MW

HYDROGEN COOLED THRI 108/44 200-260 MWTHRI 108/44 B 260-275 MWTHRI 108/55 350 MWTHW-200-2 UPTO 200 MW

HYDROGEN/WATER THW-210-2 200-219 MWCOOLED THW-235-2 220-237 MW

THDF 115/59 500-585 MWTHDF 115/55 500 MW(new)


11/50

BHEL Hardwar

Capability of Generator Modules

125/67

800


12/50

BHEL Hardwar

Library of Designs

80 MW 1000 MW

AIR COOLED

170 MW

HYDROGEN COOLED

350 MW

WATER COOLED STATOR

1000 MW

660 MW

DESIRED MW CAPACITIES


13/50

BHEL Hardwar

THRI Generators - Design features

DIRECT HYDROGEN COOLING OF STATOR CORE AND ROTORWINDING

INDIRECT COOLING OF STATOR WINDING

EXPLOSION PROOF SINGLE PIECE STATOR FRAME

END SHIELD MOUNTED BEARINGS

VPI INSULATION SYSTEM

TOP RIPPLE SPRINGS IN STATOR SLOTS TO CONTAIN BAR

BOUNCING FORCES COLD GAS TEMPERATURE CONTROL VALVE TO MAINTAIN

COLD GAS TEMPERATURE CONSTANT

RING TYPE SHAFT SEALS

STATIC/BRUSHLESS EXCITATION SYSTEM


14/50

BHEL Hardwar

THDF Generators - Design features

DIRECT WATER COOLING OF STATOR WINDING ANDDIRECT AXIAL HYDROGEN COOLING OF ROTOR WINDING

OPTIMALLY DESIGNED LEAF SPRING SUPPORT FOR CORE

END SHIELD MOUNTED BEARINGS

VPI INSULATION SYSTEM

MASSIVE SUPPORT RING FOR STATOR WINDING OVERHANGTO ABSORB SHORT CIRCUIT FORCES

SIDE AND TOP RIPPLE SPRINGS IN STATOR SLOTS TOCONTAIN BAR BOUNCING FORCES

5 STAGE AXIAL COMPRESSOR AND VERTICAL HYDROGENCOOLERS ON TURBINE END

COLD GAS AND PRIMARY WATER TEMPERATURE CONTROL

VALVES TO MAINTAIN AVERAGE INLET COOLING MEDIUMTEMPERATURES CONSTANT

DOUBLE FLOW RING TYPE SHAFT SEALS

BRUSHLESS EXCITATION SYSTEM


15/50

BHEL Hardwar

TARI Generators - Design features

# DIRECT COOLING OF STATOR CORE AND ROTOR WINDING# INDIRECT COOLING OF STATOR WINDING

# HORIZONTALLY SPLIT CASING DESIGN FOR STATOR# VERTICALLY SIDE MOUNTED COOLERS IN A SEPARATE

HOUSING# VPI INSULATION SYSTEM# SEPARATELY ASSEMBLED STATOR CORE AND WINDING

FOR REDUCING THE MANUFACTURING CYCLE# STATIC/BRUSHLESS EXCITATION SYSTEM


16/50

BHEL Hardwar

500 MW Generator on test bed


17/50

BHEL Hardwar

Gas Turbine Generator-Faridabad


18/50

BHEL Hardwar

THRI 108/39 Stator with End Shield & Terminal box


19/50

BHEL Hardwar

Main Parts of Turbogenerator

1. Stator - Stator Frame (Fabrication & Machining)

2. Core Assembly - Stator Core, Core Suspension Arrangement3. End Shield

4. Stator Winding Assembly - Stator Winding , Winding Assembly,

Connecting Bus bar

5. Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor,

Rotor Assembly

6. Completing Assembly - Bearing Assembly, Shaft Seal Assembly,

Oil Catchers, Insert Cover etc

7. Exciter

8. Auxiliary System


20/50

BHEL Hardwar


Stator

Stator Core

End Shield

Rotor

Wdg Overhang

Bearing

Shaft Seal

Terminal Bushing

Oil Catcher

Cooler

Rotor fan

Insert

Cover


21/50

BHEL Hardwar


Coolers

Terminal bushing

Foundation


22/50

BHEL Hardwar

Ventilation Circuit in THRI TG


23/50

BHEL Hardwar

Ventilation Circuit in THRI TG


24/50

BHEL Hardwar

Stator Frame

Rigid fabricated cylindrical frame

Withstands weight of core & wdg, forces & torques during operationNatural frequency away from exciting frequencies

Provision for H2/CO2 filling

Provision for temp measurements

Foot plates for supporting on foundation

provision for H2 coolers

St t F (500 MW)


25/50

BHEL Hardwar

Stator Frame (500 MW)


26/50

BHEL Hardwar

Stator Frame (Fabrication & Machining)


27/50

BHEL Hardwar

TURBINE SIDE ENDSHIELD EXCITER SIDE END

SHIELD

STATOR

TEST PRESSURE= 10 BAR FOR 30 MIN

Hydraulic/Pneumatic testing of Stator

S C G


28/50

BHEL Hardwar

Stator Frame (Air Cooled TG)

S C


29/50

BHEL Hardwar

Stator Core

Made up of punched segments of thin sheets of ETS

Punchings coated by insulating varnish

Vent segments at designed intervals for flow of cooling gas

Compressed with tension bolts, pressure plate and clamping fingers

Stepped arrangement at the end for reduction in eddy current losses

C S i THRI/THW TG


30/50

BHEL Hardwar

Core Suspension - THRI/THW TG

C S i 500 MW


31/50

BHEL Hardwar

Core Suspension - 500 MW

C S i Ai C l d TG


32/50

BHEL Hardwar

Core Suspension - Air Cooled TG

Core End Plate

Core Housing

Location forSpring

Core

E d Shi ld


33/50

BHEL Hardwar

End Shield

Closes both ends of Stator Frame

Fabricated rigid box type structure in two parts Supports and houses bearings

Provision for mounting Shaft seal body, Oil catchers, etc

Provision for supply of Bearing Oil, Seal oil, Thrust oil and its drain

E d Shi ld


34/50

BHEL Hardwar

End Shield - THRI TG

E d Shi ld (E it id 500 MW)


35/50

BHEL Hardwar

End Shield (Exciter side 500 MW)

E d Shi ld (T bi id 500 MW)


36/50

BHEL Hardwar

End Shield (Turbine side 500 MW)

B i A mbl


37/50

BHEL Hardwar

Bearing Assembly

Terminal Bushing Box 500 MW


38/50

BHEL Hardwar

Terminal Bushing Box 500 MW

New dev Total Impregnated generator


39/50

BHEL Hardwar

A VOID FREE HIGH VOLTAGE INSULATION ALON G THE ENTIRE LENGTH OF THE BAR

A MECHANICALY FIRM BOUND BETWEEN ALL WINDING

COMPONENTS AND THE INNER FRAME AND CORE BETTER SUITABILITY AGAINST THERMAL STRESSES DURING OPERATION

BETTER HEAT TRANSFER

LESS INSULATION THICKNESS - SPACE OPTIMIZED

MACHINE LIFE IMPROVES

INCREASE IN GENERATOR EFFICIENCY

INCREASE IN SHORT CIRCUIT RATIO

INCREASE IN LINE CHARGING CAPABILITY

REDUCTION IN SPARES INVENTORY - STATOR BARS AND STATOR SLOT WEDGES ARENO MORE REQUIRED AS SPARES

REDUCTION IN OVERHAULING REQUIREMENTS :

STATOR WEDGE TIGHTNESS CHECKING NOT REQUIRED

LOOSENING OF CORE AND FASTNERS REDUCED

GLUE INJECTION NOT REQUIRED

ROTOR WITHDRAWL DURING INITIAL INSPECTION NOT REQUIRED

New dev - Total Impregnated generator


40/50

BHEL Hardwar


41/50

BHEL Hardwar


42/50

BHEL Hardwar

C I ti i t St t


43/50

BHEL Hardwar

Core Insertion into Stator

Activities :-

Measurement of dimensions for alignment of Stator & Core

Welding of Springs into Stator

Placement of Impreg. Wound Core on C-Beam for deflection

Placement of Wound Core on C-Beam with packingInsertion of Stator Frame over Core with the help of Crane

Alignment of Stator with reference to Core

Welding of Bush with Spring and Core Housing

Rechecking of alignment dimensions

M Of C t lli di i


44/50

BHEL Hardwar

Meas. Of Controlling dimensions

Stator

W ldi f S i


45/50

BHEL Hardwar

Welding of Springs

Supports in the middle of Spring L-Supports at the end of Spring

W ldi f S i


46/50

BHEL Hardwar

Welding of Springs

Supports for bottomSpring

Pl t f W d C C B


47/50

BHEL Hardwar

Placement of Wound Core on C-Beam

Wound Core being placed on C-Beam Wound Core on C-Beam

I ti f St t C


48/50

BHEL Hardwar

Insertion of Stator over Core

Welding of Bush with Spring & Core Housing


49/50

BHEL Hardwar

Welding of Bush with Spring & Core Housing

AlignmentBolt Bush in position Sealing during Welding


50/50

THANK YOU

END
http://g/Documents%20and%20Settings/buzzk/Local%20Settings/Temporary%20Internet%20Files/Local%20Settings/unzipped/0%20Revisions/Corp_Overview_May_2002.ppt