PROCEEDINGS OF THE IEEE. VOL. 56. NO. 10.

OCTOBER 1968

1691

Air Cooled Two-PoleGenerators for Gas Turbine Peaking Service

Abstract-Comideratkm m the application and matching o f two-pole cylindrical rotor generators to gas turbines for peaking senice are dkussed. V a h criteria are reviewed, iaclaling generator thermal rating ad W a tiom,gas tnrbiae r a t i n g saltitude fact- cyclic Operpting duty,rapidloading coasiderptiom,generator ventilatioo ad air H t r a t i o n , mise, steadydate a d transient performance,and special generator features.

INTRODUCTION IR COOLED two-pole steam turbine driven generators have long been built to IEEE and National Electric Manufacturers Association standards to meet a narrow range of operating conditions. These generators have normally been of totally enclosed construction with integral air to water heat exchangers. Design was based on stator and rotor temperature rises giving accepted standard total temperatures based on an ambient air temperature (air leaving heat exchangers)of 40C. Cooling air heat transfer wasbased on air density corresponding toan altitude 3300 of feet. The standard generator rating was matched to the steam turbine rating at design steam conditions. Modifications of generator rating were rare, and due primarily to operations at altitudes greater than 3300 feet or cooling water temperatures greater than 95F (35C). The gas turbine uses compressed and heated air as the power medium. Power output is a function of air flow, pressure, and temperature. The maximum temperature to which the air can be heated before entering the turbine is limited by metallurgical considerations. Hence, for a given limiting turbine speed and inlet air temperature, power output will depend upon air density and pressure, and greater output can normally be obtained withreduced ambient inlet air temperature and/or altitude. For a given altitude and turbine inlet temperature, a curve can be plotted of power output versus ambient inlet air temperature. Fig. 1 shows a family of typical curves for various turbine inlet air temperatures. Note the considerable increase in power output at lower ambient air temperatures.

c
n
I -

g
K
LL c
VI x

Fig. 1. Typical gas turbine performance versus ambient temperature.

AMBIENT TEMPERATURE

O F

power. Output

the windings can be maintained and higher temperature rises allowed if the temperature of the cooling air is reduced. Present standardsfor air cooledtwo-pole generators limit the stator winding temperature rise by resistance temperature detector to 60C over a 40C ambient. The rotor winding temperature rise is limited to 85Cby resistance over a 40C ambient. These give total temperature limits of 100Cfor the stator and125Cfor the rotor. The use of room air cooled or open generator construction allows us to make use of the lower ambient temperature toachieve greater power output without exceeding the established total temperature limits. Knowledge of the change in generator stator and rotor winding temperature rise with change in load allows us to calculate a theoretical load at each ambient temperature that will give us the same GENERATOR THERMAL RATING rated winding total temperature. Such a theoretical rating For most operating conditions, the two-pole generator is curve is shown in Fig. 2. Fig. 2 was plotted on the basis of constant power factor a thermally limited device. Increased electrical output will result in a proportionate increase in losses and winding operation. It is based on equivalent thermal loading of the with a 40Cambient temperature. It is aptemperature rise. Thus, the total temperature limitations of stator and rotor parent that for such a design, the output is limited at reManuscript received September 18, 1967. This was Paper 68 CP duced ambient temperatures by the rotor heating and at 126-PWR presented at the 1968 IEEE Winter Power Meeting. It was ambient temperatures above 40C by the stator heating. referred to the PROCEEDINGS by the Power Generation Committee of the Comparative ratings of peaking gas turbines are usually IEEE Power Group. based on an ambient temperature of 80F (27C). A generaThe authors are with the Electric Machinery Mfg. Company, Minneapolis, Minn. 55413 tor design based on a 40C ambient becomes somewhat

1692

PROCEEDINGS O F THE IEEE, OCTOBER 1968

A 110
0

w 100

2
90
z
W

80

60 20

40

80 100 AMBIENT TEMPERATURE 'f

120

Fig. 2. Generator load for constant total winding temperature.

unbalanced at an ambient temperature of 80F with the rotor windings more heavily thermally loaded than the stator windings. From the theoretical standpoint, it would appear that if the designer were to utilize a lower ambient temperature as the basis for his design, optimization would dictate a somewhat different approach to obtain the most Fig. 3. Suggested generator loading versus ambient temperature. economical machine configuration and size. In actuality, the design must be balanced to best achieve a match with the gas turbine output rating curve. quite small. One rule of thumb is that the rating of a generaSo far ourdiscussion has considered only the total wind- tor can be increased approximately one percent per200 ing temperature as a basis for generator rating. However, meters below the standard altitudeof lo00 meters. This inthe temperature rise itself becomes a limiting factor even crease in rating is about one half of the increase in output though the total winding temperature has not beenexobtained when a gas turbine is operated at a lower altitude. ceeded. Giving due consideration to the preceding factors, a sugAs machine loading and generator winding temperature gested generator output versus ambient temperature curve rise increases, the difference between the hottest point in the is shown in Fig. 3. For a given design,the base rating would winding and its average temperature also increases. In con- be adjusted to suit the site altitude. It is understood that ventionally cooled generators, the stator temperature rise this curve is based on intuitive judgement and experience, usually is based on detectors embedded between the upper and not on factors that can be calculated or predicted acand lower coil sides in the slots. Jerrard [2] has shown that curately. the temperature indicated by such detectors is somewhat MATCHING TURBINE AND GENERATOR RATINGS less than the actual copper temperature, due to thermal Fig. 1 showed typical gas turbine output curves as a funcgradient in the main winding insulation. This difference will increase with generator loading, so we must also in- tion of ambient temperature for different limiting turbine crease the temperature margin to keep the hot spot tem- inlet temperatures. In effect, each curve corresponds to a perature within limits. different operating life for the turbine. For practical purAs we increase the temperature rise on a given generator, poses these curves can be replaced by two basic onesfor an the differential temperature between the windings and operating guide. The base load or normal rating curve coradjacent parts increases. Thus, the effects of thermal ex- responds to relatively long time periods between turbine pansion must be considered in the development of a final inspections or overhaul. This might be in the neighborhood generator rating curve [11. Winding and insulation stresses of SO00 operating hours. The other operating curve might increase rapidly with increasing temperature rise. The be called the peaking or maximum output curve, based on effects of rotor winding deformation due to heating after an operating lifebetween inspections ofless than 1000 hours. the application of centrifugal force must be seriously examined [3]. In addition, the effects of these increased stresses Since the economics of gas turbine peaking power apare aggravated by the cyclic nature of gas turbine peaking plications are based primarily on providing kilowatt outapplications. It is expected that the generator will be loaded put at minimum installed cost, it is common practice to and unloaded hundreds of times during its operating life. match the generator to the gas turbine rating on its normal At lower altitudes the increased density of air results in a or base load curve at 80F ambient and 1OOO-footelevation. slight improvement in heat transfer rate in an electric ma- This is shown in Fig. 4. To utilize the maximum output chine. However, since the thermal gradient at heat transfer curve of the turbine, the generator excitation should be surfaces in a conventionally cooled turbogenerator is limited so thatthe operating power factor approaches usually only 20 to 30 percent of the total temperature rise, unity. Note that it is necessary to use a larger generator to it isevident that any change in rating due to site elevation is utilize the turbine capability at lower ambient temperatures.

SMITH AND DOESCHER: TWO-POLE GENERATORS FOR GAS TURBINE PEAKING

1693

20

40

60
AMBIENT TEMPERATURE

80

100

120

- OF Fig. 4. Power output versus ambient temperature for gas turbine and generator matched at 80F ambient and 1000-foot altitude.

MECHANICAL CONSIDERATIONS One of the prime advantages of the gas turbine for peaking applications is its ability to be started and stopped quickly. The gas turbine generator set is loaded rapidly, often achieving full load in less than two minutes after receiving the signal tostart. Naturally, this severecyclic loading must be considered in the design of the air cooled two-pole generator. The stress levelof mechanical parts must be considered in the light ofwide temperature extremes and very rapid thermal expansion. It is expected that the generator will start and operate to its capability without adverse effects on its operating life regardless of the ambient temperature at the time of startup, the speed of such a startup, orthe number of timesthat this condition is repeated. Rotor forging transition temperatures, fatigue limits, stress levels, and mechanical configuration must be carefully considered. The fits between parts must be made with consideration for the wide range of temperatures exbe pected. Bearings and the lubrication system must designed to operate regardless of ambient temperature. GENERATOR VENTILATION Preventing the buildup of dirt and other foreign substances within the generator is important to insure long trouble-free life. The volume of cooling air required is quite high and the air is distributed internally for maximum cooling efficiency. Because of mechanical limitations, the cooling ducts within the generator rotor are small and part of the rotor windings are subjected directly to the flow of cooling air. Buildup of dirt or other foreign particles can

plug these cooling ducts, reducing the cooling efficiency. In addition, severe dirt buildup could minimize the electrical creepage distances maintained within the rotor. Hence, filters are used to remove as much dirt as possible from the outside air drawn into the generator. Filter area is made as large as possible to give maximum filtering efficiency. The filters may be either of the viscous cleanable type or of the fiber or bag replaceable type. Filter maintenance must be strictly followed to allow full air flow and generator cooling andto prevent premature buildup of dirt within the generator. Obviously, dirt buildup will be more rapid in terms of hours of operation than with a totally enclosed water cooled machine, but because of the reduced operating time, generator cleanliness consistent with years of installation will be comparable. In some cases, particularly with larger generators, it may be advantageous to recirculate some or all of the generator cooling airto minimize the wide temperature changes possible. Thermostatically controlled louvers can be used to prevent natural circulation of air through thegenerator during shutdown and assist the space heaters in maintaining the generator shutdown temperature well above the outside ambient air temperature. These louvers can then be used to recirculate cooling air discharged from the generator to prevent the air entering the generator from dropping below a specified temperature, such as 60" to 70F. Not only does t h s air recirculation reduce the possible temperature differential seen by the mechanical parts of the generator, but it can also in some cases raise the minimum temperature to which the generator will besubjected and allow

1694

PROCEEDINGS OF THE IEEE, OCTOBER 1968

a moreeconomic choice in materials such as the rotor forging with regard to transitiontemperatureandthe possibility of brittle fracture. GENERATOR NOISE Because of the high rotor peripheral velocity and large number of cooling ducts in a two-pole generator, its inherent broad-band noise level will be quite high. In addition, a very high noise component at twice line frequency (i.e., 120 Hz for a 60-Hz generator) is inherent. To achieve two-pole magneticconfiguration on the rotor,the windings are inserted in slots milled between the center line of the pole faces. This gives a stiff bending moment with the pole axis vertical and a somewhatlessstiffbendingmoment with the pole axis horizontal. This results in a change in rotor deflection twice per revolution with the attendant double frequency vibration whichis transmitted directly to the cooling air in the air gap and mechanically to the generator bearings and bearing supports. In addition, the magnetic attraction and repulsion on the stator punchings OCTAVE MIDFREOUENCY BAN0 - Hz the as field revolves introduces another double frequency vibration which is transmitted to the generator frame and Fig. 5 . Typical open generator noise level in decibels at 7 feet referenced to 0.0002 microbar. to the air passing through the stator ventilation passages. Isolation of this mechanical core vibration from the generatormounting feet by means offlexible mounting is lo( standard on larger generators. However, this flexible 90 mountingcannot eliminate the noise generated by the w 80 vibrating core itself and transmitted directly to the cooling 2 air. 2 70 > Thus the air cooled two-pole generator, without sound 5 60 attenuating equipment, will exhibit noise source levels ? 50 similar to those shown in Fig. 5 with the peak sound power level occurring at twice line frequency in the range of 120 to 40 130 dB. Considerable deviation from Fig. 5 can occur with 30 different generator sizes and mechanical configurations. 0 0.5 1.0 1.52.5 2.0 3.0 INRUSH LVWCENERATOR kVA RATING To meet even minimal soundcriteria, the generator coolFig. 6. Minimum and restored voltages with sudden application ing air inlet and discharge must be acoustically treated. of low PF load. Based on no initial load. Approximately 20- to 3 0 d B higher noise levels are transmitted from the generator air discharge so acoustic treatment there is considerably more extensive than at the air inlet. In addition, where strict residential sound levels must to utilize an oversize, or low-reactance, generator to be met, itis often necessary to enclose the generator withn achieve adequate voltage performance. Fig. 6 shows typical two-pole generator transient voltage an acoustic treated house. performance for both adirect connected exciterand a static GENERATOR PERFORMANCE or brushless excitation system with minimum and restored Many gas turbine generators are installed not only for voltages shown as a function of the ratio of applied load peaking service, but also to provide startup power for an inrush to generator rating. In the power range of 3 MW adjacent steam power plant, or emergency power for nuclear through 40 MW, inherent reactances for air cooled genplant auxiliary motors. Two-pole generators are inherently erators are very similar and little deviation from Fig. 6 low-reactance machines and exhibit good transient voltage would normally be expected. Economic studies of most gas turbine peaking installaperformance upon the sudden application of load. However, when usedto start the auxiliaries of a steam power plant, the tions have indicated that the standard 0.5 excitation system starting sequence and motor inrushlevels may be such that speed of response is adequate. Typical peaking units are adequate voltages cannot be achieved with a standard gas not large compared with total powersystem generating turbine generatorcombination even though the gas turbine capacity, and their possible contribution to system stability has sufficientpower output to match the combinedfull can not be sufficient to justify the cost of a high-response load rating of the auxiliaries. In this case it may be necessary excitation system.
IU

DOESCHER: AND SMITH

TWO-POLE TURBINE PEAKING GENERATORS GASFOR

1695

bracket bearing design allows shipment as a complete assembled unit. This allows the lifting or skidding of the complete generator to the foundation where onlyalignment and grouting is required. Threading of the rotor into the stator can be eliminated. Many gas turbine sets are built as power plants complete with turbine and generator control and switchgear devices installed and connected. The various components of the h i s conplant can be installed and interconnected quickly. T struction permits rapid installation and economical movement of the plant to a different location in the future. In fact, some plants have been built on highway trailers or rail cars.
0

10

20

30

40

70 80 PERCENT KILOWATTS

50

60

90

100 110 120

Fig. 7. Synchronous generator 0.85-PF reactive capability. 100 percent=rated kVA in 104F (4OC) ambient.

GENERATOR PROTECTION The gas turbine generator is usually installed as part of a remote control, semiautomatic or completely unattended operation. Since the capability of the turbine at the site elevation and operating ambient temperature is frequently greater than the generator capability, and since emergency and peaking operation often requires substantial reactive power to sustain system voltage, it is important that automatic thermal protection of the generator be installed. This may operate from direct measurement of generator temperature. Usually it is simpler and adequate to bias the voltage regulator circuits to keep generator operation within its reactive capability curve. Fig. 7 shows a typical reactive capability curve for lagging power factor operation. Special circuits can be used in the voltage regulator to permit operation at leadingpower factor. Reactive capability curves for such operation are usually based on stability considerations for the particular application.

CONCLUSIONS The application of a two-pole air cooled cylindrical rotor generator to a gas turbine driver is considerably different than that historically used for application with steam turbines. Considerable confusion exists regarding the differences in ratings of two-pole generators and gas turbines with regard to ambient temperature and altitude. Limitations in extension of generator rating have not been established. Whileconsiderable study has been made of the effect of ambient temperature extremes, rapid loading, continuous cyclic operation, noise, and other factors, no standards have beenset by either the user or the industry. The generahis design and rating tor manufacturer muststillbase methods upon historic steam turbine generator standards and optimum economic choice often cannot be given to the ultimate user. Specifications for gas turbine sets often reflect confusion and can impose an economic penalty on both the manufacturer and the user. It is highlyrecommended, in light of the rapidly expanding application of gas turbine generator sets, that well thought out and meaningful standards be established by both industry and the user for the application of two-pole generators to gas turbine peaking sets.
REFERENCE

INSTALLATION AND MAINTENANCE [l] J. S. Johnson and J. C. Botts, Physical effects of thermal cycling on stator coil insulation of turbinegenerators, Trans. AZEE (Power One of the attractive features of any gas turbine generator Apparatus and Systems), vol. 75, pp. 249-253, June 1956. installation is its packaged design. These units are in- [2] R. P. Jerrard, Temperature drop to resistance temperature detectors in stator windings of turbine generators, Trans. AIEE (Power A p stalled in a wide variety of locations, many of them very paratus and Systems), vol. 73, pp. 665670, June1954. remote. The generator design must be simple and allow for [3] J. G. Noest, Prevention of rotor-winding deformation on turbomaximum ease of installation and maintenance. Twogenerators, Trans. AZEE, vol. 63, pp. 514517, July 1944.