500 MW Generator, Salient Features.

1) 2) 3) 4) 5) 6) 7) The generator at 500 MW C.S.T.P.S. has following salient features: Brushless Excitation System Micalastic Insulation of Stator Conductors Use of Oxygen free water for Stator cooling and Hydrogen for rotor cooling. Provision of Polishing unit for primary water system, which maintains the pH of primary water between 8 and 9 Provision of Seal oil system on both Air side as well as Hydrogen side. Provision of flash evaporator on CO2 filling line Generator circuit breaker opens when RPP relay operates, in case of Turbine trip.

Specifications:

Generator Type Apparent Power Active Power Current Voltage Speed Frequency Hydrogen Pressure Continuos permanent unbalanced load
Rectifier Wheel: No. of rectifier wheels No. of diodes per wheel No. of fuses per wheel Generator Volume: Generator Gas Volume CO2 filling quantity H2 filling quantity

Main Exciter ELR/70/90-30/620ES 3840 KW 6300 Amp 600 V 3000 rpm -

Pilot Exciter ELP 50/42-30/ 16 E7 65 KVA 195 Amp 22022 V 3000 rpm 400 Hz -

THDF 115/59 588 MVA 500 MW 16.2 KA 21 KV 1.05KV 3000 rpm 50 Hz 3.5 Kg/ cm 8%

:2 : 60, (800 V, 800 A) : 30

: 80 m : 160 m, (s.t.p) : 480 m, (s.t.p.)

General Design Features of the generator: Stator Frame: Stator frame consists of cylindrical center section and two end shields. Stator end shields are joined with frame by flange connection. O rings provide the sealing for making the joint gas tight and pressure resilient. Stator core, winding and Gas Coolers are mounted on the frame. The frame is welded to feet, which in turn are rigidly bolted with the foundation.

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Stator Core: Stator core is made from insulated electrical sheet steel laminations. It is mounted in supporting rings over insulated dove tailed guide bars. Axial compression of the stator core is obtained by clamping fingers, pressure plates and non-magnetic clamping bolts. The bolts are insulated from core. The supporting rings form part of an inner frame cage. The cage is supported in the outter frame by a large number of separate flat springs distributed over the entire core length. The springs are so arranged and tuned that core vibrations resulting from magnetic field are not transmitted to the frame and foundation. Stator Winding: The stator bars, phase connectors and bushings are water-cooled. Bars are composed of separately insulated strands, which are transposed by 540 in the slot portion and bonded together with epoxy resins. Bars consist of hollow as well as solid strands, distributed over the cross- section for obtaining good heat dissipation. At the bar ends, solid strands are jointly brazed into a connecting sleeve. Hollow strands are strands are brazed into water boxes from where cooling water enters and exits. Teflon hoses connect the water boxes to Inlet and outlet manifolds. Bars are inserted in the slots with side ripple springs, slot bottom equalizing strip, and top ripple spring beneath the wedge. Gaps between end windings are completely filled with insulating material and cured after installation. For radial support, the end windings are clamped to to rigid support ring of insulating material which, in turn, is fully supported by frame. The bars are clamped with support ring with pressure plates, the plates are held together by clamping bolts, made from high strength insulating material. The support ring is free to move axially within the frame caused by thermal expansion of stator bars. The stator winding connections are brought out on 6 Bushings in a welded, non-magnetic compartment below the generator. Hydrogen Cooling Circuit: Cooling of stator: Please ref. diagram No. 1. Hydrogen is circulated in the generator interiors in a closed circuit by a multistage axial flow fan, mounted on the Turbine end of the rotor. Hot gas is drawn by the fan from the air gap and delivered to the coolers. From cooler outlet, gas devides in three paths. Path 1: Flow of gas is directed into the rotor at the turbine end below the fan hub for cooling of Turbine end half of the rotor. Path 2: Flow of gas is directed to individual frame compartments for cooling of stator core. Path 3: Flow of gas is directed to the stator end winding space at the exciter end, through guide ducts in the frame for cooling of exciter end half of the rotor and of the core end portions. The three flows mix in the air gap, from where it is drawn to coolers by the axial fan. Cooling of rotor: Cold gas is directed to the end windings of the rotor at Turbine end and Exciter end. Openings are provided before the rotor body ends. Hydrogen flows through cooling ducts of each conductor. Hot gas discharges in to the air gap at the center of the generator through the holes provided on the conductors and wedges. Cooling of stator frame: Gas flows in to the individual frame compartments for core cooling, and exits in to the air gap.

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Rotor Winding: It consists of several coils inserted in to slots and series connected such that two coil groups form one pole. Each coil is made from several series connected turns. Conductors are hollow and made from silver bearing, de-oxidized copper. Two numbers of lateral cooling ducts are also provided for each slot. L- shaped strips of laminated epoxy glass fibre fabric with nomex fillers are used for slot insulation. Slot wedges are made of high conductivity material and extend below the shrink seat of retaining ring. Seat of the retaining ring is silver plated to ensure good contact between slot wedge and retaining ring. System acts as a damper winding. Retaining ring is made of non-magnetic, high strength steel. The retaining rings are shrunk fit to the rotor body in the overhang position. Field current is supplied to the rotor winding through radial terminal bolts. Field current leads are connected to the exciter leads through Miltikontakt plug in contacts. Generator operating parameters are as given below.

Parameter Stator core temperature Stator slot temperature Primary water temp, winding outlet Hot gas temp., cooler inlet Cold gas temp, cooler outlet ? T between cold primary water and cold gas Bearing metal temp. Absolute Bearing Vibrations Cooling water temp. before Hydrogen cooler Cooling water temp. after Hydrogen cooler Co2 and H2 filling rate

Normal Operating <90 50 to 80 <65 40 to 75 25 to 34 >5 <75 <50 <39 <46 150 m/ H

Limiting Value

Action if limiting value is crossed

Unit C C C C C C C m C C

70,

1C 120 90 39 46

Generator is Deexcited manually Trip Trip Trip Trip

Seal oil System: Diagram No. 2 shows the seal oil system. The system consists of two nos. of Air side AC seal oil pumps, One no. of Hydrogen side AC seal oil pump and one D.C. Seal oil pump which supplies oil to air side seal ring in case of AC failure. During normal operation, air side AC pump draws seal oil from Seal Oil Storage Tank (SOST) and feeds it to the shaft seals through coolers and filters. Oil drains from the annular space between shaft and seal ring in the air side, which is returned to SOST. Hydrogen side seal oil pump draws the oil from Hydrogen side seal oil tank and feed sit to the seal ring on Hydrogen side, through coolers and filters. Oil drains towards Hydrogen side through the annular gap between shaft and seal ring. The oil is first collected in the prechambers and then returned to Hydrogen side seal oil tank. Air side seal oil gets saturated with air. But, by providing sealing from Hydrogen side also, the air-saturated oil does not enter in to the Hydrogen side, thus maintaining Hydrogen purity. For ensuring that Air side seal oil does not drain in to the generator, seal oil pressure in air circuit ia kept slightly less than that of Hydrogen side. In the event of non-availability of
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Hydrogen side pump, air side pump supplies oil to Hydrogen side seal ring. Hydrogen side and air side seal oil circuits are in contact with each other in the annular gaps between the shaft seals. Seal oil pressure at the air side shaft seal is set slightly higher than Hydrogen side seal oil pressure, hence a small quantity of oil continuously flows from air side seal to Hydrogen side seal through the annular gap. This causes gradual increase in the quantity of oil in Hydrogen side circuit. A float valve in Hydrogen side seal oil tank returns excess oil to SOST. But this interchange is so small that it does not impair the advantages of two different circuits. Oil pressure in air side seals is 0.8 to 1.2 Kg/ cm higher than gas pressure in generator casing and is controlled by the valve called A, (valve 4 in the diagram). Separate valve, (C Valve, mentioned at 11 in the diagram) also maintains the oil pressure in H2 side seal rings at 0.8 to 1.2 Kg/ cm above the gas pressure in generator casing. Pressure equalising valve, (Valve 8 in the diagram) maintains the constant differential pressure between airside and Hydrogen side seal oil. Seal Oil system parameters:

Normal Value Discharge Pressure, H2 side seal oil pump Discharge Pressure, air side seal oil pump Seal oil temp. after H2 side cooler Seal oil temp. after air side cooler H2 side seal oil temp 10 9.0 40 to 45 40 to 45 40 to 69

Tripping Value

Unit Kg/cm Kg/cm C C C

55

Primary Water System: Please ref to fig.3. The purpose of primary water system is to circulate cooling water through the conductors of the generator stator. The primary water tank mounted on the top of generator casing, acts as storage for the primary water and is connected to the suction of Primary water pump. Pump circulates water, through cooler and filter to inlet manifold, from where water enters in to the Hollow conductors. Conductors are connected to inlet manifold through flexible Teflon hoses. Hot water is discharged from the conductors in to outlet manifold, from where it flows in the primary water tank. Outlet manifold is also connected to hollow conductors through Teflon hoses. Primary water also cools the bushings. Space above the primary water in the tank is filled with ultra pure Nitrogen gas, pressure of which is maintained at 0.1 to 0.15 Kg/ cm with the help of pressure regulating valve. Specifications of primary water quality are: 1) 2) 3) Water conductivity in the circuit Dissolved Oxygen pH : Less then 4.0 mho / cm : Less then 100 ppb. : 8 to 9

Purpose of using Oxygen free water is to prevent corrosion of Copper conductors. Purpose of Nitrogen: Dissolved Oxygen in the D. M. Water, used for initial filling of the system or for subsequent make up, is very high. Hence, after filling the system or taking make up in the system, water is first scrubbed with Nitrogen to remove the Dissolved Oxygen. In this operation, conductors and
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bushings are first isolated from the primary water circuit. Pump then establishes water flow through re-circulation line. The dissolved oxygen from water gets liberated and mixes with Nitrogen in the tank. The nitrogen is purged out by fresh gas from the ultra pure Nitrogen cylinder, after every 30 minutes. The process continues till dissolved Oxygen in the water reduces to specified value. Then the main circuit is established. The second purpose of the Nitrogen is to provide inert atmosphere in the tank. Hydrogen gas diffuses in to primary water through the Teflon hoses, which accumulates in the primary water tank. Nitrogen thus provides inert atmosphere to this Hydrogen. Alkalizer Unit: Even after using Oxygen free water does not prevent copper corrosion completely. Alkalizing the water can reduce the severity of corrosion. Hence Alkalising unit is provided in these generators, to maintain pH between 8 and 9. Diagram no. 2, shows a connection branched off from primary water circuit before pump and consisting of Ion Exchanger 9.Water, after passing through ion exchanger, again mixes with primary water in the main circuit. The diagram below explains the functioning of this branch.

From Primary water Tank

Tank containing NaOH solution

Main circuit Treatment Circuit

Ion Exchanger

Diaphragm Pump

NaOH

Primary water pump

To Generator conductors

To the small quantity of primary water tapped from main circuit (1 to 1.3 Kg/s) is injected with NaOH solution by the diaphragm pump. This water is passed to ion exchange unit, which consist of anion and cation resins. It removes all copper, iron, chlorine and carbon dioxide ions from water. But it also removes Na+ ions and hence, to maintain concentration of Na + ions, NaOH solution is injected. This maintains pH, but conductivity of water increases. Diaphragm pump stops when conductivity of water in main circuit reaches 2.5 S/ cm or in treatment circuit it reaches 3.0S/ cm. Primary Water Filters: Primary water circuit is provided with a magnetic filter. It consists of strainer type filter with magnet bars. Strainer has a mesh size of 75 m. Magnet bars are made of strong permanent magnets. The filter retains iron particles. Fine filter giving degree of filtration of 5 m is provided

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after the ion exchange unit of the treatment circuit. Important Parameters of primary water circuit are:

Primary water temp. Primary water pump pressure. Flow rate to treatment ckt. Conductivity after ion exchanger Conductivity in main ckt. Level in primary water tank Primary water flow in stater winding Primary water pressure in stator winding D.P. across stator winding Primary water flow in bushing Pressure in primary water tank
Brushless Excitation System: The exciter consist of 1) 2) 3) 4) 5)

Normal Operating 65C 8 Kg/ cm 1 1.3 Kg/s 2.5S/cm 2.2S/cm 75% 18 Kg/s 2.6 Kg/ cm 1.2 to 1.5 Kg/ cm 0.42Kg/s 0.2 Kg/ cm

Limit 70C 5 Kg/ cm 0.015 3.0S/cm 2.5S/cm 14.4 Kg/s

Action on reaching limit value Alarm S/B pump picks up Diaphragm pump stops Diaphragm pump stops Diaphragm pump stops Generator trip

0.37 Kg/s

Generator trip

Rectifier wheels Three phase main exciter Three phase pilot exciter Cooler for exciter air cooling Metering and measuring equipment.

Diagram 3 shows the brushless excitation system. The Pilot exciter, is a permanent magnet, three-phase generator. Output voltage is then fed to AVR, where it is rectified and controlled. Variable DC current from AVR is used for excitation of three-phase Main Exciter. In main exciter, field winding is arranged on stator and 3-phase AC voltage is induced on the rotor. This voltage is further fed to the rectifier wheels mounted on the same shaft to which main exciter is coupled. The DC voltage from rectifier wheels is then fed to Generator field winding through the dc leads arranged in the rotor shaft. The leads are run through the shaft bore. Rotor leads and rectifier leads are connected with each other through Multikontakt assembly, which consists of plugin bolts and sockets. Mechanical coupling of the two shafts also couples the leads. The silicon diodes on the rectifier wheels are arranged to form 3-phase bridge circuit. Two diodes are connected in parallel and mounted on Aluminum heat sink. One fuse is connected for two diodes and failure of one diode blows the fuse. Fuse indicator pops up under such circumstances. For supervision of fuses, stroboscope arrangement is made. For suppression of voltage peaks arising out of commutation, RC network is provided on the wheels. The insulated wheels serve as +ve and -ve buses. The complete exciter is housed in an enclosure through

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which cooling air is circulated. Tripping and Protection scheme: In case of Turbine Tripping, Generator circuit breaker opens on operation of Reverse power protection relay. Only in case of electrical protections of the generator, GCB opens without the operation of RPP relay. Generator Mechanical Protections: These protections cause tripping of Turbine first and GCB opens on RPP protection. 1) High cold gas temperature in Generator casing 2) Liquid in Generator Terminal Box 3) High hot air temperature in Exciter unit 4) High seal oil inlet temperature 5) High primary water Inlet temperature 6) Low primary flow rate at Winding outlet 7) Low primary water flow rate at Bushing outlet

Generator Electrical Protections:

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