This document provides an overview of generator development. Some key points: - Michael Faraday first conceptualized AC generators in 1831, and Sir Charles Parson developed the first turbo generator in 1889. Generating capacity increased over time with improvements in materials and cooling techniques. - Hydrogen gas cooling allowed generators to scale up to 275MW by the 1950s. Key advantages of hydrogen are that it is over 13 times more effective at cooling than air. - Modern generators can exceed 1000MVA in capacity and use hydrogen cooling, water cooling, sealed oil systems, and other technologies to dissipate heat and improve efficiency up to 98.6% at full load. Diagrams illustrate components like the rotor, stator,

1. WELCOME TO PRESENTATION ON
GENERATOR

2. GENERATORGENERATOR
DEVELOPMENTDEVELOPMENT
 FIRST A.C GENERATOR CONCEPT WAS ENUNCIATED BY MICHAEL FARADAYFIRST A.C GENERATOR CONCEPT WAS ENUNCIATED BY MICHAEL FARADAY
IN 1831.IN 1831.
 FIRST TURBO GENERATOR WAS DEVELOPED BY SIR CHARLES A.PARSON INFIRST TURBO GENERATOR WAS DEVELOPED BY SIR CHARLES A.PARSON IN
1889.1889.
 IN 1922 GENERATOR RATING WAS INCREASED TO 20MW AT 300 RPM BYIN 1922 GENERATOR RATING WAS INCREASED TO 20MW AT 300 RPM BY
USING SOLID FORGING & IMPROVED TECNIQUESUSING SOLID FORGING & IMPROVED TECNIQUES
 BY THE OUTBREAK OF SECOND WORLD WAR, IN 1939 LARGE GENERATORBY THE OUTBREAK OF SECOND WORLD WAR, IN 1939 LARGE GENERATOR
WERE DEVELOPED OF 30 TO 50 MW AT 3000RPM WITH AIR COOLING.WERE DEVELOPED OF 30 TO 50 MW AT 3000RPM WITH AIR COOLING.
 PROBLEM OF ECONOMIC IN OF GENERATOR, DESIGNER WERE FACINGPROBLEM OF ECONOMIC IN OF GENERATOR, DESIGNER WERE FACING
PROBLEM OF INCREASING IN RATING AND LIMITATION OF SIZE & WEIGHT.PROBLEM OF INCREASING IN RATING AND LIMITATION OF SIZE & WEIGHT.
 BREAK THROUHG TECHNIQUE OF USING HYDROGEN AS COOLING MEDIUMBREAK THROUHG TECHNIQUE OF USING HYDROGEN AS COOLING MEDIUM
INSTEAD OF AIR INCREASED THE RATING OF GENERATOR UPTO 275MW.INSTEAD OF AIR INCREASED THE RATING OF GENERATOR UPTO 275MW.
FIRST OF HYDROGEN COOLED GENERATOR OF 60MW WAS INSTALLED INFIRST OF HYDROGEN COOLED GENERATOR OF 60MW WAS INSTALLED IN
U.K IN 1949.U.K IN 1949.
 LARGEST: THDF 115/78 AT KKW TRILLO 1147 MVA, IN OPERATION SINCE 1988LARGEST: THDF 115/78 AT KKW TRILLO 1147 MVA, IN OPERATION SINCE 1988
ALSO AT GOESGEN SINCE 1978.ALSO AT GOESGEN SINCE 1978.
 THDF 125/78: 1250 MVA AT FRIMMERSDORF & AT BOXBERGTHDF 125/78: 1250 MVA AT FRIMMERSDORF & AT BOXBERG

3. GENERATORGENERATOR
PRINCIPAL:PRINCIPAL:
A.C GENERATOR OR ALTERNATOR IS BASED UPON THE PRINCIPAL OFA.C GENERATOR OR ALTERNATOR IS BASED UPON THE PRINCIPAL OF
ELECTROMAGNETIC INDUCTION GIVEN MICHAEL FARADAY IN 1831.ELECTROMAGNETIC INDUCTION GIVEN MICHAEL FARADAY IN 1831.
FIRST LAWFIRST LAW
WHEN EVERY A CONDUCTOR CUT A MAGNECTIC FIELD EMF IS INDUCTED INWHEN EVERY A CONDUCTOR CUT A MAGNECTIC FIELD EMF IS INDUCTED IN
IT.IT.
SECOND LAWSECOND LAW
EMF INDUCED IS DIRECTLY PROPORTIONAL TO RATE OF CHANGE OF FLUXEMF INDUCED IS DIRECTLY PROPORTIONAL TO RATE OF CHANGE OF FLUX
LINKAGES.LINKAGES.
EQUATION :EQUATION :
E = 4.44*E = 4.44*ΦΦ**F*N.F*N.
F = Pn/120F = Pn/120
E = INDUCED EMFE = INDUCED EMF
ΦΦ = STRENGTH OF MAGNETIC FIELD IN WEBERS.= STRENGTH OF MAGNETIC FIELD IN WEBERS.
F = FREQUENCY IN CYCLES PER SECOND OR HERTZF = FREQUENCY IN CYCLES PER SECOND OR HERTZ
N = NUMBER OF TURNS IN COIL,N = NUMBER OF TURNS IN COIL,
P = NUMBER OF POLESP = NUMBER OF POLES
n = REVOLUTION PER minuten = REVOLUTION PER minute

4. STATOR PMG
ROTOR
DAVR
MAIN EXCITER
P.T & C.T
LINE DIAGRAM OF 500MW GENERATOR
TO GENERATOR TRAFO
CC BOLT
DIODE
WHEEL
ROTOR
STATOR

5. 0 25% 50% 75% 100%
99
98.64
98.5
98
97.5
97
LOAD IN MW : % FULL LOAD
η %
GENERATOR EFFICIENCY

6. TOTAL LOSSES IN GENERATOR TOTAL TO 6920 KW.
BREAK UP AS FOLLOWS:
IRON LOSSES 600
KW.
SHORT CIRCUIT LOSSES 2800 KW.
EXCITATION LOSSES 1390
KW.
WINDAGE LOSSES 1680 KW.
BEARING & SEALS LOSSES 450
KW.
EFFICIENCIES
FULL LOAD AND AT 75% FULL LOAD:
98.63%
AT 50% FULL LOAD : 98.44 %.
AT 25 % FULL LOAD: 97.5 %
GENERATOR EFFICIENCY

7. TOTAL LOSSES IN GENERATOR TOTAL TO 6920 KW.
GENERATOR EFFICENCY
AS LOSSES ARE DISSIPATED IN THE FORM OF HEAT (APPROX 6.9 MW).
EFFECTIVE COOLING MEDIUM IS NEEDED
COOLING WITH HYDROGEN GAS
STATOR WATER COOLING(PRIMARY WATER).
HYDROGEN GAS
COOLING THE STATOR & ROTOR AIR GAP ROTOR WINDING.
PRIMARY WATER
STATOR WINDING & BUSHINGS.

8. HYDROGEN
 WHY HYDROGEN IS USED IN GENERATOR.
HYDROGEN IS 13.6 TIMES MORE EFFECTIVE COOLING
MEDIUM THAN AIR.
HYDROGEN BECOME EXPLOSIVE MIXTURE WHEN MIXED
WITH AIR.
HYDROGEN PURITY SHALL BE MORE THAN 97%.
TO AVOID MIXTURE OF AIR & HYDROGEN GENERATOR IS
SEALED WITH OIL AT THE SHAFT.

9. SEAL OIL SYSTEMSEAL OIL SYSTEM
• GENERATOR IS SEALED WITH THE OILGENERATOR IS SEALED WITH THE OIL
AT THE SHAFTAT THE SHAFT
• HYDROGEN IS DOUBLE SEALED WITHHYDROGEN IS DOUBLE SEALED WITH
OIL CALLED AIR SIDE & H2 SIDEOIL CALLED AIR SIDE & H2 SIDE
• OIL PRESSURE IS MAINTAINED 1.5OIL PRESSURE IS MAINTAINED 1.5
KSC MORE THAN HYDROGEN (3.5KSC MORE THAN HYDROGEN (3.5
KSC).KSC).

10. CONSTRUCTION OF GENERATORCONSTRUCTION OF GENERATOR
• STATOR CORESTATOR CORE
• STATOR SLOTSTATOR SLOT
• STATOR WDG BARSTATOR WDG BAR
• ROTOR SLOTROTOR SLOT

11. 0.4
1.0
LAG
MVAR
LEAD
MW
0.7
0.85
0.9
0.95
0.95
100 300 500
450
RATED
MAX
H2 PRESS.
3.5 BAR
588
200
400
CAPABILITY CURVE

13. ROTORROTOR

14. STATORSTATOR

15. HYDROGEN COOLING PATHHYDROGEN COOLING PATH
COMP BLADES

16. ROTOR SLOT COOLINGROTOR SLOT COOLING
I/L
T.E
O/L
E.E

17. VENTILATION SCHEMEVENTILATION SCHEME
WATER OUTLETS
H2
COMPRESSOR SIDE
A
B C
D

18. C.C BOLTC.C BOLT

19. PMG (PERMANENT MAGNETIC GENERATOR)PMG (PERMANENT MAGNETIC GENERATOR)

20. DIODE WHEEL RECTIFIERDIODE WHEEL RECTIFIER

21. MAIN EXCITERMAIN EXCITER

22. PRIMARY WATERPRIMARY WATER
SYSTEMSYSTEM

23. TERMINAL BOXTERMINAL BOX
PHASE
BUSHING
PW OUTLET
PW INLET
PHASE CONNECTOR
FLEXIBLE
CONNECTOR
PTFE HOSE

24. THDF TG : H2 SHAFT SEAL
END SHIELD
INSULATION
RING CARRIER
PACKING
SEAL RING
PRESS OIL
SHAFT
H2

25. SEAL OIL SYSTEMSEAL OIL SYSTEM

26. GENERATOR COREGENERATOR CORE

27. STATOR SLOT
SLOT WEDGE
TOP RIPPLE SPRING
& PACKERS
SIDE RIPPLE SPRING
SEMI COND. WRAPPER
TOP BAR
BOTTOM BAR
HOLLOW CONDUCTOR
SOLID CONDUCTOR
SEMI-CONDUCTING
160
48

28. STATOR WINDING BAR
MICALASTIC INSULn.
HOLLOW STRIP
SOLID STRIP
45
50
4.6
5
8
1.6
5.85
1.3

29. ROTOR SLOT
COPPER ALLOY
WEDGE
TOP PACKER
CONDUCTOR
SLOT LINER
INTER-TURN
INSULATION
BOTTOM
PACKERS
196
141
50.9
36.6
30

30. THDF: STATOR CORE - 2THDF: STATOR CORE - 2
PLATE SPRING
BASKET
CORE BAR
SHUNT
STUD
PRESS
RING
D1330 D26305850 (5592)
86 DUCTS
3

31. STATOR CORESTATOR CORE
CAGE
FLAT SPRING
CORE BAR

32. COMPRESSOR BLADESCOMPRESSOR BLADES