Generator description for Tosiba manufacturer.ppt

GENERATOR
Classroom Lecture Series for Steam Turbine Generator TOSHIBA
1
4. GENERATOR

GENERATOR
2
CONTENTS
4.1 DESCRIPTION OF THE GENERATOR
4.1.1 GENERATOR DESIGN
4.1.2 GENERATOR CONSTRUCTION
4.1.3 GENERATOR MONITORING INSTRUMENTS
4.1.4 GENERATOR INSPECTION AND
MAINTENANCE
4.2 EXCITATION SYSTEM
4.2.1 DESCRIPTION OF EXCITATION SYSTEM
4.2.2 AVR CUBICLE
4.2.3 EXCITATION SYSTEM MAINTENANCE
CONTENTS

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4.1 DESCRIPTION OF THE GENERATOR
DESCRIPTION OF THE GENERATOR
4.1.1 GENERATOR DESIGN

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GENERATOR DESIGN
Air Cooling System (Capacity: 170 MVA or Less)
Hydrogen Cooling System (Capacity: Between 170 and 350 MVA)
(For Direct Rotor Winding and Indirect Stator Winding)
Water Cooling System (Capacity: More Than 370 MVA)
(For Stator Winding)
TYPES OF GENERATOR COOLING SYSTEMS

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GENERATOR DESIGN
a.Type
b.Cooling System
c.Excitation System
d.Rating
- Nominal rated capacity
- Power factor
- Rated hydrogen pressure
- Number of phases
- Frequency / Speed
- Terminal voltage
- Shot circuit ratio
- Insulation class-Stator
- Temperature rise
e.Cooling Gas Data
- Cooling Gas Flow Rate through Generator
- Cooling gas inlet temperature
- Cooling gas outlet temperature
f.Water Flow Through Stator Winding (If Applied)
g.Cooling Gas (Hydrogen/Air)Cooler
- Quantity
- Cooling water flow rate per unit
- Total cooling water flow
- Cooling water inlet temperature
- Cooling water outlet temperature
- Head loss
DESIGN DATA ITEMS

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4.1.2 GENERATOR CONSTRUCTION
GENERATOR CONSTRUCTION

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CROSS SECTION
Collector
& Brush
H2 Gas Cooler
Rotor
Stator Core
Bearing
Stator Frame
Stator Winding
Rotor Winding

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SPRING SUPPORT OF STATOR CORE
Stator Core
Flange
Key Bars
Section Plates
Spring Plates
Core
Laminations

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CONNECTION OF STATOR WINDING
Neutral
Line

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STATOR WINDING COOLING WATER FLOW
Collector
Side
Supply
Water
Drain
VENT
Return
Water
Turbine
Side
Upper Coil
Inlet
Header
Outlet
Header
Bottom Coil

GENERATOR
Wedge
Slide Wedge
Filler
Hollow Copper Strand
Solid Copper Strand
Grand Insulation
Side Filler
Filler Between Crossovers
Vertical Separator
Filler Strip
11
STATOR COIL
Stator Frame
Cross Section Of
Stator Coil
Stator
Coil Assembly(Transposition Arrangement)
RTD or Filler

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STATOR END WINDING SUPPORT SYSTEM
Stator End Winding
Nose Ring
Binding Ring
Binding Ring
Support
Permanent Ring
Strap
Inner End Shield
Core End
Core End
Flange
Support
Brackets
Sliding Pin
Sliding Pin
Bearing Pad
Support
Brackets
Sliding
Directions
Glass Fiber Strapping

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TERMINAL BOX
Lead
Connection
Ring
Flexible Lead
High Pressure Area
LOW PRESSURE AREA
Terminal Box
Terminal Box
Bottom Plate
High Voltage
Bushing
Low Pressure Area
3 Pieces per
Each Bushing

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14
Connector
In
Holes
Out
VENT TUBU
Guiding Disc
Duct
In
Insulator
Tube
Flange
B.C.T
Conductor
BUSHING
Vent Tube
Seal
3 Pieces per
Each Bushing

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Shaft Rotor Wedge
Retaining
Ring
Field(Rotor)
Winding
Axial
Flow
Fan
Balance
Weight
Iron Core
Cross Section
Axial Flow Fan
Mounting Position
ROTOR ASSEMBLY

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CONNECTION OF ROTOR WINDING
Pole 1
Pole 2
Collector Ring
Internal (+)
Terminal Stud
Collector Ring
External(-)

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17
ROTOR COIL END
DUMPER RING
Creepage
Block
Retaining
ring
Armortisseur Insulation
To Collector Ring
Coil End
End ring
Support
Coil
Slot

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18
DIRECT-CONDUCTOR-COOLED ROTOR
Wedge
Creepage Block
Inlet Scoop
(Cooled Gas) Rotation
Flush Inlet
Scoop
Turn
Insulation
Outlet
Region
Extruded
Copper
Channel
Slot
Armor
Inlet
Region
Creepage
Block
Wedge

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COLLECTOR RING
Exhaust
Handle
Brush
Collector Ring
Brush Holder
Cooled
Air

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BRUSH
Terminal
Pigtail Wire
Brush To Be Replaced(Consumed Brush)
Low Pressure
Spring
New
Brush
Brush Holder

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H2 GAS COOLERS
COOLER- A
COOLER- B COOLER- D
COOLER- C
TURBINE END
TOP VIEW
COLLECTOR END
C1
C2
C6
C5
C7
C8
C4
C3

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22
ROTOR & STATOR COOLING ZONE
H2 Gas Cooler
Rotor Fan

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23
Gap Baffle
Cold Gas
Hot
Gas
Hot
Gas
Rotor
Stator Core
STATOR SEGREGATING BAFFLE

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24
BEARING ASSEMBLY Generator BRG
(Turbine Side)
Generator BRG
(Exciter Side)
Steady Support
(Exciter Bearing)

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BEARING
Turbine
Side
Inside
Collector
Side

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26
Turbine
Side
Inside
Collector
Side
SEAL CASING

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Turbine
Side
Inside
Collector
Side
INNER OIL DEFLECTOR

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Turbine
Side
Inside
Collector
Side
OUTER OIL DEFLECTOR

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Turbine
Side
Inside
Collector
Side
BEARING RING

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Turbine
Side
Inside
Collector
Side
ALIGNMENT KEY

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HYDROGEN SEAL

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BEARING BRACKET

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33
GENERATOR COOLING WATER SYSTEM
H2 Gas Coolers
Stator Cooling
Water Coolers

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GENERATOR MONITORING INSTRUMENTS
4.1.3 GENERATOR MONITORING
INSTRUMENTS

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- STATOR COIL TEMPERATURE: RTD
- H2 GAS TEMPERATURE: RTD
- STATOR CORE END TEMPERATURE: TC
- BEARING METAL TEMPERATURE: TC
- BEARING VIBRATION DETECTOR: Gap Sensor

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36
STATOR COIL RTD (1/2)
Wedge
Stator Core
Upper Coil
Insulation
RTD
Bottom Coil
RTDs Are Installed Between The
Upper Coil And Bottom Coil.

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STATOR COIL RTD (2/2)
RTD
STATOR WEDGE
Maintain spaces
where detectors
are not provided.
White Red
TOP COIL
BOTTOM COIL
RTD:Platinum

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38
Cross Section Of Stator Frame
RTD For
H2 Gas
Coolers
RTDs Are Arranged In The Ventilation Course Entrance
Of Each H2 Gas Cooler.
HYDROGEN GAS RTDs

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HYDROGEN GAS COOLER RTDs
COOLER A COOLER C
COOLER B COOLER D
RTD
C1
RTD
C5
RTD
C2
RTD
C6
RTD
C4
RTD
C8
RTD
C3
RTD
C7
RTD’s are not
provided.
Cold gas temp. not
controlled automatically.
Total of 8 RTD’s
are used for
monitoring

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40
STATOR CORE END THERMOCOUPLES (1/2)
Gen. Center
Packing Gland
Packing Gland
Lead Pipe
View From Turbine End
Detector
Marker Tube
Marker Tube
Packing
Gland
Terminal
Thermocouples Are Provided at
The Stator Core End.

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41
Stator Winding
Wedge
Copper Shield Stator Clamping Plate
Outside Space Block
Stator Core
Core End
Thermocouple
STATOR CORE END THERMOCOUPLES (2/2)

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BEARING METAL THERMOCOUPLES
Thermocouple Thermocouple
BRG
Metal

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BEARING VIBRATION DETECTORS
Vibration
Detector
Bearing And Steady
Support Are Equipped
With Vibration Detectors.

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44
GENERATOR INSPECTION AND MAINTENANCE
4.1.4 GENERATOR INSPECTION AND
MAINTENANCE

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PERIODIC INSPECTIONS
& TESTS FOR THE GENERATOR
1. Generator Inspection During Each Shift
2. Daily Generator Inspection & Test
3. Weekly Generator Inspection & Test
4. Generator Inspection & Tests Every 3 to 6 Months
5. Generator Inspection & Tests Every 6 to 12 Months
6. Complete Generator Inspection During Scheduled Shutdown

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46
1. Generator Inspection During Each Shift
(1) Check the water pressure and water temperature of each gas cooler,
and vent out the air collected in the cooler.
(2) Visually check the condition of the generator collector rings and brushes.

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2. Daily Generator Inspection and Test
(1) Turn the handle on the seal oil filter.
(2) Check the difference between the generator hydrogen pressure
and the seal oil pressure.
(3) Check the oil level in the vacuum tank and oil trap chamber.
(4) Check the drain indicator window of the drain alarm inside the generator.
(5) Check the hydrogen purity meter and the hydrogen flow meter indications.
(6) Check the operation and oil level of the vacuum pump and open the drain
in the drain separator.
(7) Check the brushes and collector rings.

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3. Weekly Generator Inspection and Test
(1) Test that the emergency seal oil pump starts.
(2) Test the various hydrogen alarms.
(3) Check the air filters at the generator brush and collector cooling air intake.

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4. Generator Inspection and Test Every Three to Six Months
(1) Calibrate the hydrogen gas purity meter on the hydrogen control board.
(2) Check the alarm contacts at the hydrogen control board.
(3) Change the oil in the vacuum pump and in the reduction gears.
(4) Refill the float the drain alarm in the generator interior and expansion
tank with oil, and check the alarm operation.
(5) Measure the insulation resistance of the generator bearing insulation
and seal casing insulation for the collector side.

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50
5. Generator Inspection and Test Every Six to Twelve Months
(1) Test the operation of the alarms on the hydrogen control board.
(2) Perform leak tests for hydrogen gas, including the generator.
(3) Calibrate the hydrogen and seal oil control device meters.

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6. Complete Generator Inspection During Scheduled Shutdown
(1) The person in charge of overhauling work, or the inspector, should affix their
signature to the inspection report upon completion of each item.
(2) Work not performed or work not applicable is to be excluded from the report.
(3) The work sequence may be changed depending on the conditions.

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ADJUSTMENT OF BRUSH HOLDER GAP
15mm
Brush
Pigtail
Wire
Holder

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REPLACING BRUSHES DURING OPERATION
CAUTION: A brush should be replaced if its top is 15mm below the edge of
the brush holder opening ( i.e. the remaining brush length is 55mm. )
When replacing brushes while the generator is in operation, removal of
magazines, one at a time, from a single pole is permissible.
CAUTION: Do not remove more than one magazine from a pole at a time.
Brush replacement should be performed under the supervision of a competent
engineer or an experienced operator.

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54
HYDROGEN GAS COOLER TROUBLESHOOTING
Symptom
Potential
Causes
Countermeasures
Generator
Operation
Feasibility
Water
leakage
from water
box
Loose bolts ;
Deteriorated
gasket
Additional
torquing ;
Gasket
replacement
Possible ;
Stop Operation
Corrosion and
pitting of cooling
tube
Plugging Stop Operation
Water
leakage
from tube
bundle
Loose joint
between tube and
tube sheet
Flaring Stop Operation
Fouled tubes Tube cleaning Stop Operation
High cooling
water
temperature
Reduction of
generator load
Possible
Generator
overheating
Air pocket in the
top of water box
Air venting Possible

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AIR FILTER INSPECTION & RECYCLING
Filter
Frame
Stud Bolt
Holder
Wing Nut
Air Filter Unit
Air Flow Direction
Detailed View Of Air Filter

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EXCITATION SYSTEM
4.2 EXCITATION SYSTEM
4.2.1 DESCRIPTION OF EXCITATION SYSTEM

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DESCRIPTION OF EXCITATION SYSTEM
TYPE OF EXCITATION SYSTEM
DC Excitation System
Rectifier Excitation
System
Excitation
System
AC Excitation System
Brushless Excitation System
Self-Excited AC Generator System
Thyristor Excitation System

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EXCITATION SYSTEM KEY ONELINE
G
AVR
Generator
GEN
Transformer
Excitation
Transformer
GEN.
C.B.
CT's
PT’s
DIGITAL AVR
FCB Thyristor
Component Equipment
- Automatic Voltage Regulator (AVR)
- Thyristor Rectifier
- Field Circuit Breaker (FCB)
- Excitation Transformer

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DIGITAL-AVR EXCITATION SYSTEM
G
TRD PHC PLA
PIO
SYSTEM
BUS
MC
SC
GENERATOR
GEN
TRANSF.
EXCITATION
TRANS.
GEN.
C.B.
ABBREVIATIONS
SC: SYSTEM CONTROLLER
MC: MASTER CONTROLLER
PHC: PHASE CONTROL UNIT
PLA: PULSE AMPLIFIER
TRD: TRANSDUCER
CT's
PT’s
FROM UNIT
CONTROL
SYSTEM
PLANT
INTERFACE
DIGITAL AVR
FIELD
THYRISTOR

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AVR CUBICLE
4.2.2 AVR CUBICLE

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AVR CUBICLE
Ａ
Ｖ
Ｒ
ｃ
ｕ
ｂ
ｉ
ｃ
ｌ
ｅ
Internal arrangement
POWER
DISTRIBOTION
RY-UNIT
BP
U-ISO
DUCT
DUCT
RADIATOR UNIT
T T
5
T T
1
T T
6
T T
2
T T
7
T T
3
T T
8
T T
4
MC-B
(9 SLOT)
MC-A
(9 SLOT)
S.C
(19 SLOT)
PWU-B
BP
PWU-A
8
7
6
5
4
3
2
1
FAN UNIT
ARRANGEMENT
OF AVR

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AVR CUBICLE
Device Functions
AVR
(Automatic Voltage Regulator)
To adjust the terminal voltage by automatic
voltage regulator (90R).
UEL
(Under excitation limit)
To prevent the generator from phase -lead
operation under low field current.
OEL
(Over Excitation Limiter)
To prevent the generator from phase -delay
operation under high field current.
VPFL
(V/F Limiter)
To limit overfluxing of the generator and
the generator transformer.
PSS
(Power System Stabilizer)
To add a delta-P stabilizing signal to AVR.
AFU
(Automatic Follow-up of 90R)
To make 90R of the standby system
follow that of the working system.
MEC
(Manual Excitation Controller)
To adjust the field current by manual
voltage regulator(70R).
CONTROL FUNCTIONS
RCC
(Reactive Current Compensator)
To add a voltage droop characteristic
according to reactive current

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AVR CUBICLE
System Controller
COM80
CHO CH1
GIF2
CHO
GPIB
CH0
COM85
CH2
DDCP03
B
CH0
COM85
CH2
DDCP03
B
CN1
EL
Display
Master
Controller
- A
Master
Controller
- B
LOCAL INTERFACE

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64
EXCITATION SYSTEM MAINTENANCE
4.2.3 EXCITATION SYSTEM
MAINTENANCE

GENERATOR
Indicator Explanation
A channel selected This is lit when A-system master
controller is in operation.
B channel selected This is lit when B-system master
controller is in operation.
AVR in service This is lit when AVR is in use.
AFU in service This is lit when AFU is in use.
PSS in service This is lit when PSS is selected.
Field circuit breaker
closed
This is lit when the field circuit breaker
is closed.
Generator circuit
breaker closed
This is lit when the generator
circuit breaker is closed.
OEL operated This is lit when the
overexcitation limit (OEL) is in
operation.
UEL operated This is lit when the
underexcitation limit (UEL) is in
operation.
VPFL operated This is lit when the V / F over
voltage limit (VPFL) is in operation.
STATUS INDICATION OF EL DISPLAY FOR AVR
65

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66
No. Inspection Items to be confirmed Frequency
1 Visual check ① Are environmental conditions of specification met?
② No dust has accumulated?
③ No direct sun light?
④ No corrosive gas?
⑤ Is ventilation good?
⑥ No vibration?
Any time
2 Check mounting
condition
① Fastenings are tight?
② Connector firmly mounted?
③ Cable and wiring intact?
At regular inspection
3 Check on power unit ① Input/output voltage within the specified range?
②Ripples within the specified range?
4 Check on interface with
external circuit
①Check the level of analog input signal.
②Check the sequence of contact signal.
③Are these signals input to TOSMAP correctly?
5 Components ①Is [RUN] LED lit?
②Is the input/output characteristic good?
③Is the program uncorrupted?
④Are set values unchanged? Check on ③ and ④
is made by comparing the memory card and the
floppy disk.
6 Others ① Are lamps and indicators functional?
② Is the operation of relays normal?
③ Are there any anomalies with other devices?
MAINTENANCE AND INSPECTION FOR AVR

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67
THYRISTOR RECTIFIER
FRONT VIEW RIGHT SIDE VIEW
COOLING FAN
AIR EXHAUST AIR EXHAUST
DC BUS DUCT
AC BUS DUCT
AIR FILTER
DC BUS DUCT
COOLING
AIR INLET
THYRISTOR
UNIT

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68
THYRISTOR BRIDGE
● ● ●
● ●
● ●
●
●
●
●
●
●
●
●
●
●
● ●
●
●
●
●
●
U
V
W
●
P
N
TRAY
THYRISTOR
TRAY

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THYRISTOR FAN REPLACEMENT
REPLACING THE UPPER FAN REPLACING THE LOWER FAN

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70
THYRISTOR TRAY WITHDRAWAL
CAUTION:
BE SURE TO USE THE
THYRISTOR LIFTER
OUTLINE
REMOVAL
MOUNTING

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FIELD CIRCUIT BREAKER CUBICLE

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74
FIELD CIRCUIT BREAKER POSITION
The circuit breaker compartment has three functional positions:

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EXCITATION TRANSFORMER
Ventilator
Net
HV Terminals
LV Terminals
Panel
Nameplate
Nameplate
HV BCT

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79
END GENERATOR

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