- A generator and a turbine are acquisition for life, they run for over 30 years in a plant; - However acquisitions made without properly evaluate aspects like temperature, insulation class, construction and efficiency, have made big companies rip money instead of make more earnings; - 0.2% efficiency in a year roll can means 100 KUSD/year in energy that could be invoiced, how could it be ignored? - Those slides try to explore expects about how to select the right generator;

1. SELECTING THE PROPER GENERATOR
ANNUAL CONGRESS OF ….
EVANDRO BRULLING - BRUSH
JEFFERSON JOEICEMIR – BRUSH

2. Who are BRUSH? Who am I?
© BRUSH Group
BRUSH Electrical Machines
Manufacture and service generators, power management systems and transformers.
Celebrating 140 years, up to 1.100 MVA, 2 & 4 poles
BRUSH HQ, UK
-2 Pole Generators
-Transformers
-PMS / Control Systems
-Aftermarket Support
BRUSH HMA, Netherlands
-4 Pole BRUSH Generators
-3rd
Party Generators
-Aftermarket Support
BRUSH SEM, Plzen CZ
-2 Pole Generators
-Hydrogen & Air Cooled
-Skoda Factory
-Aftermarket Support
- Evandro Bulling / Jefferson Joeicemir – BRUSH employees Americas

3. Motivation to this presentation….

4. Procurement chain
© BRUSH Group
End User
* Energy business
* Business plan
* Own the project
* Operates
* Sell electricity
* Engineer
* Procurement
* Construction
EPC
Main
component
A
Main
component
B
Turbine
Manufacturer
Generator
manufacturer
Buy via commodity teams
to maximize profit

5. As effect
© BRUSH Group
Stone, G. C., et al. "Recent problems experienced with motor and generator
windings." Petroleum and Chemical Industry Conference, 2009. PCIC 2009. 2009
Record of Conference Papers-Industry Applications Society 56th Annual. IEEE, 2009.
1962 to
2010 over
16 folds

6. As effect
© BRUSH Group
Generator
manufacturer
End User
* Reduced conductor sections
* Reduced insulation thickness
* Reduced steel
* Reduced manufacturing time
* Spec and no more philosophy
* Less efficiency
* Higher maintenance cost
* More unplanned outages
* Higher OPEX
* Less performance
Turbine
Manufacturer

7. The Challenge – How to maximise OPEX and CAPEX ?
© BRUSH Group
- Temperature of windings
- Insulation class
- Rotor construction
- Power Factor influence
- Line and Neutral Cubicle
- Generator efficiency
- Temperature of windings
- Insulation class
- Rotor construction
- Power Factor influence
- Line and Neutral Cubicle
- Generator efficiency
SELECTING THE PROPER GENERATORSELECTING THE PROPER GENERATOR

8. What is the importance of maximum cooler inlet
water temperature?

9. Generator Output vs. Coolant Temperature
Inlet water and output – DAX GENERATORS
Coolant Inlet Temperature - °C
© BRUSH Group
58MW

10. When one say insulation F and F/F, is there any
difference ?

12. Are there different rotor constructions and any
consequence on performance

13. ONE PIECE FORGED SHAFTONE PIECE FORGED SHAFT
- Less vibration
- Less heating
- Less vibration
- Less heating
Test bay ( mm/s)
0.5 – 0.9 1.3 – 1.5
Temperature delta in Celsius
About 10 to 15 degrees

14. What is the power factor influence by selecting a
generator?

15. POWER FACTOR – A MECHANICAL ANALOGY
ELECTRICAL DESIGN – DAX GENERATORS
© BRUSH Group
Glass–Cables
Foam
Cos
ϕ
Beer

16. Power Factor Selection
© BRUSH Group

17. © BRUSH Group

18. Where we install the line and neutral cubicle?
Q5

20. Can generator efficiency influence projects
payback time? What is a typical generator
efficiency?

21. © BRUSH Group

22. © BRUSH Group
100MW, 2 poles, 13.8 kV,
inlet Water 30C, Insulation F/B, FP 0.85
Example 1 50USD/MWh
Example 2 70USD/MWh
Output
(MW)
Efficiency
(%)
Available
(MW)
8000h/year
Mwh
Example 1
50USD/Mwh
Example 2
70USD/Mwh
100 0.96 96 768*103
USD 38.4*106
USD 53.76*106
100 0.98 98 784*103
USD 39.2*106
USD 54.88*106
Saving 800 KUSD 1120 KUSD

23. Summary – How to maximise OPEX and CAPEX ?
© BRUSH Group
- Correct inlet water
temperature
- Insulation F/B
- Forged shaft construction
- Correct Power factor
- Line & Neutral Cubicle
attached to generator
- Efficiency of at least 98%
- Correct inlet water
temperature
- Insulation F/B
- Forged shaft construction
- Correct Power factor
- Line & Neutral Cubicle
attached to generator
- Efficiency of at least 98%
SELECTING THE PROPER GENERATORSELECTING THE PROPER GENERATOR
End User
- 30 and over operational life
years
- 10 – 20% saving on
maintenance
- 50 - 200 KUSD saving on
installation costs
- Efficiency savings that may
guarantee generator
payback in less than 2y
- 30 and over operational life
years
- 10 – 20% saving on
maintenance
- 50 - 200 KUSD saving on
installation costs
- Efficiency savings that may
guarantee generator
payback in less than 2y

24. Thank you for your time and attention.
Any questions?