CONSTRUCTIONAL FEATURES OF GENERATOR ROTOR AND ITS COOLING SCHEME

Electrical Machines Engineering caters to the need of turbo-generators with rating from 50 MW to 800 MW sets for thermal, gas and nuclear power plants. Existing Sets (Rating wise breakup) :
RATING TOTAL ORDERS COMMISIONED

500 MW

THDF

42 SETS
69 SETS 125 SETS 17 SETS 6 SETS

27 SETS
33 SETS 125 SETS 15 SETS 6 SETS

210/250MW THRI 210/200/235 THW 140-160 MW TARI 100 MW

MODULE SIZE (THRI 108/44) GIVES THE SIZE OF THE MACHINE.

108 X10 = 1080 (1075) ROTOR OUTER DIA 44X100 = 4400 CORE LENGTH

GENERAL ARRANGEMENT OF AIR COOLED TURBOGENERATOR

GENERAL ARRANGEMENT OF 660 MW TURBOGENERATOR

GENERAL ARRANGEMENT OF 500 MW TURBOGENERATOR

DESCRIPTION Max. continuous MVA Rating Max continuous MW rating Rated terminal voltage (KV) Rated Stator current (Amps)

210 MW THW 247 210 15.75 9050

235 MW THW 264 237.7 16.5 9240

210 MW THRI 247 210 15.75 9050

250 MW THRI 294.1 250 16.5 10291

500 MW THDF 588 500 21 16166

Power factor Lagging

Exciter current at MCR (Amps) Exciter Voltage at MCR (V) Rated hydrogen pressure (atm) Rated speed (rpm)

0.85
2600 310 3.5 3000

0.9
2755 326 3.5 3000

0.85
2080 265 2.0 3000

0.85
2386 319 3.0 3000

0.85
4040 340 3.5 3000

DESCRIPTION Max. continuous MVA Rating Max continuous MW rating Rated terminal voltage (KV) Rated Stator current (Amps)

350 MW THRI 412 350.2 22 10812

660 MW THRI 776 660 21 21334

800 MW THRI 1000 800 27 21383

Power factor Lagging

Exciter current at MCR (Amps) Exciter Voltage at MCR (V) Rated hydrogen pressure (atm) Rated speed (rpm)

0.85
3094 374 6.0 3000

0.85
5587 445 6.0 3000

0.8
5864 434 6.0 3000

3-D MODELLING OF ROTOR ASSEMBLY AND COMPONENTS

PLATFORM USED PRO ENGINEER

WILDFIRE 2.0

TYPICAL ROTOR ASSEMBLY

ROTOR SHAFT

FAN BLADES

RETAINING RINGS

WEDGES

FIELD LEAD

ROTOR SHAFT

BARREL

COUPLING
(TURBINE END)

BLOWER HUB

COUPLING

MATERIAL 26NiCrMoV145

(EXCITER END)

Y p = 730-830N/mm2

ROTOR SHAFT TURBINE END

TE COUPLING

JOURNAL

COUPLING TURBINE END

SPIGOT

12 HOLES

BARREL

POLE 1

BALANCING HOLES

BARREL CROSS POLE SLOTS(MOON SLOTS)

VENTILATION HOLES

BARREL

SLOT FOR PARTITIONS

BARREL
SLOTS ( PARTITION)

MAIN SLOTS 28 NO.

BALANCING HOLES

BARREL (Contd.)

SLOTS
(VENTILATION)

HOLE ( C.C. BOLT)

SLOTS ( DAMPER WEDGES)

BARREL (Contd.)

HOLES (COOLING OF END ZONE)

HOLE FOR LOCKING OF PRESSURE PLATE

BARREL (Contd.)

HOLES (VENTILATION)

HOLES (BALANCING)

RETAINING RING SEAT

BARREL (Contd.)

SECTION OF INCLINED HOLES

(COOLING END ZONE)

BLOWER HUB
GROOVE FOR BALANCING WTS

HOLES FOR LOCKING OF BLADES

COUPLING EXCITER END

STEPS FOR HYDROGEN SEALING SPIGOT

14 HOLES

FIELD LEAD CORE BAR

THREADED HOLE FOR C.C. BOLT

FIELD LEAD CORE BAR

INSULATING CYLINDER

INSULATING PARTITION

CURRENT CARRYING BOLT

FIELD LEAD WITH H2 SEALING ARRANGEMENT

O RINGS

CONTACT PIN

INSULATING COVER

FIELD LEAD CORE BAR

INSULATING COVER

FIELD LEAD WITH H2 SEALING ARRANGEMENT (Contd.)

HOLE FOR HE LEAK TEST

THREADED RING

THREADED RING PACKING

FIELD LEAD CONNECTION TO ROTOR COILS (Contd.)

ROTOR COIL A

FLEXIBLE CONNECTION

INSULATING

FIELD LEAD

TUBE

CURRENT CARRYING BOLT

ROTOR COIL

MATERIAL SILVER BEARING COPPER SIZE 36.8X9.6mm Y p = 245 N/mm2

RADIAL SLITS
EDGEWISE BENDING

ROTOR COILS

BRAZED JOINT

ROTOR COIL CROSSSECTION 500 MW ROTOR

REDESIGN OF THW-210 MW TG ROTOR FOR KAHALGAON

EXISTING REDESIGNED

1. 2. 3. 4. 5.

SLOT WEDGE TOP LINER ROTOR SHAFT SLOT BOX BOTTOM LINER

ROTOR COILS (210/250 MW ROTOR)

COLL A TO G (7 COILS) PER POLE

RADIAL COOLING

ROTOR SLOT FILLING

SLOT LINER

SLOT ANGLE ROTOR COILS

SLOT ANGLE

MATERIAL GLASS CLOTH AND NOMEX PAPER

SLOT ANGLE

TAPERED AT ENDS

TOP SLOT LINER

HOLES FOR VENTILATION

ROTOR WEDGES

MACHINING OF END SLOT WEDGES

ROTOR WEDGES (Without Rotor Shaft)

DAMPER WEDGE

DAMPER WEDGE

SLOT WEDGE

PRESSURE PLATE

ROTOR WEDGES (CONTD.)

DAMPER WEDGE (short) DAMPER WEDGE

SLOT WEDGE (END)

SLOT WEDGE

SLOT WEDGE

HOLES FOR VENTILATION

END WEDGES

MACHINING FOR RETAINING RING SEATING

DAMPER WEDGE

MACHINING FOR KEY RING SEATING

ROTOR SHAFT WITH WEDGES

ROTOR END WINDING

1. ROTOR BODY 2. SNAP RING 3. RETAINING RING 4. ROTOR WINDING

5. END WDG INSULULATION 6. FILLER 7. END RING 8. BALANCING WEIGHTS

OVERHANG SPACERS
END SPACERS

SPACERS

PARTITION

POLE SPACERS

POLE SPACER

MATERIAL GLASS TEXOLITE

SPACER ASSEMBLY

NOMEX PIECES

SPACER

MATERIAL GLASS TEXOLITE

OVERHANG WEDGES

WEDGE

NOMEX PIECES

MATERIAL GLASS TEXOLITE

WEDGE

NOMEX PIECES

WOUND ROTOR

OVERHANG ASSEMBLY

RETAINING RING ASSY.

RETAINING RING

CENTERING RING

MATERIAL X8CrMnN1818k

MATERIAL

33NiCr Mo145

SECTIONED VIEW
RETAINING RING AND CENTERING RING ASSY

COOLING SCHEME

COOLING IN END PORTION

BOTTOM CANAL

THROUGH VENTILATION SLOT TO AIR GAP COLD ZONE

HOT ZONE

COOLING OF OVERHANG PORTION

PARTITION ASSEMBLY

UPPER PARTITION

LOWER PARTITION

BLOWER BLADE ASSY.

BLOWER BLADE FORGING

BLOWER BLADE

BLOWER BLADE

BLADE PROFILE

THREADED PORTION

FLAT FOR LOCKING

ROTOR COIL

INCLINED COOLING DUCTS IN SLOT PORTION

COOLING DUCT IN OVERHANG

TYPICAL OVERHANG COMPLETE

RECTANGULAR COILS

RECTANGULAR COIL ASSEMBLY

COIL B TO G CONNECTIONS

COIL B TO COIL C

COIL C TO COIL D

COIL G -COIL G

COIL F -COIL G

COIL E -COIL F

COIL D TO COIL E

OVERHANG WEDGES (INTERIOR VIEW)

STOPPER FOR WEDGES

STOPPER FOR SPACERS

DOUBLE INDENT WEDGE SINGLE INDENT WEDGE

TRAPEZOIDAL SLOT SHAPE

PARALLEL SLOT

EXISTING

EXISTING NINE SHAPES NEW SHAPE OVERHANG

NEW SHAPE SLOT