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BHEL Haridwar
Electrical Machine Engineering 1
- Rakesh Kumar
BHEL Haridwar
Electrical Machine Engineering 2
125/67
800
Capability of Generator Modules
115/67
93/38 108/39 108/44
108/55108/44 (VPI)
250
115/52
BHEL Haridwar
Electrical Machine Engineering 3
1. Generator Module – THRI 108/44
270 MW Turbo Generator
BHEL Haridwar
Electrical Machine Engineering 4
2. Operating Parameters Parameters 250 MW 270 MWRated Voltage 16.5 KV 16.5 KVStator Current (Amps) 10291 11115Rotor Current (Amps) 2497 2666Rotor Voltage (V) 299 325SCR 0.63 0.58Hydrogen Pressure (bar) 4 4Heat Load (KW) 2650 2900Stator Wdg Temp (°C) 93 98Rotor wdg Temp (°C) 81 84.5Core temp (°C) 65 67
270 MW Turbo Generator
BHEL Haridwar
Electrical Machine Engineering 5
END SHIELD
OPENING FOR
COOLERS
STATOR CASING
Design Constraints & Solution (270 MW)
BHEL Haridwar
Electrical Machine Engineering 6
Design Constraints & Solution (270 MW)
ORIGINAL CONTOUR
NEW CONTOUR
BHEL Haridwar
Electrical Machine Engineering 7
• Stator Winding Bars with 540° Transposition & 2-Plane Bending: THRI designs so far manufactured by BHEL are with 360°/single plane transposition. Adoption of 540° transposition leads to manufacturing simplicity as strip to strip brazing is eliminated.
Design Features (270 MW)
BHEL Haridwar
Electrical Machine Engineering 8
540° Transposition of wdg conductors (270 MW)
540 Deg Transposition
Strip to strip brazing is eliminated.
BHEL Haridwar
Electrical Machine Engineering 9
Cooler Parameters - Parameters 250 MW 270 MWInlet Water temp (°C) 38 38Cold gas temp (°C) 45 43Cooling Water Flow m3/hr 280 350
Special Features –1. Special fin configuration has been developed.2. Pitching has been reduced and manufacturing shall be
done in close tolerances. 3. Cold gas temperature achieved shall be below normal
requirement.
More Efficient Coolers (270 MW)
BHEL Haridwar
Electrical Machine Engineering 10
1. 540° transposition of winding conductors 2. Elimination of strip to strip brazing leading to manufacturing
time cycle reduction3. Strengthening of stator winding overhang4. Total VPI core and stator windings5. More efficient twin Hydrogen coolers6. Increase in transportation weight – 3 Tons (approx)
Design Features (270 MW)
BHEL Haridwar
Electrical Machine Engineering 11
525 MW TURBO GENERATOR
PW TankWater Cooled Stator Winding
Compressor(on TE only)
End Shield Mounted Bearings
Terminal Bushings
Rotor
Stator Core
Module – THDF 115/59
BHEL Haridwar
Electrical Machine Engineering 12
1. Generator Module – THDF 115/592. Operating Parameters Parameters 500 MW 525 MWRated Voltage 21 KV 21 KVStator Current (Amps) 16291 16981Rotor Current (Amps) 4040 4213Rotor Voltage (V) 340 355SCR 0.52 0. 49Heat Load (KW, H2 Coolers) 4639 4963
Hydrogen Pressure (gauge) 3.5 4.0Primary Water Flow(m3/hr) 65 75Shaft Seal System Double Flow Single Flow
525 MW TURBO GENERATOR
BHEL Haridwar
Electrical Machine Engineering 13
600 MW Generator
Module – THDF 115/67
BHEL Haridwar
Electrical Machine Engineering 14
Better ratio of overall core length to effective core length
Axial Cooling of Stator Core
BHEL Haridwar
Electrical Machine Engineering 15
Axial Cooling of Stator Core
BHEL Haridwar
Electrical Machine Engineering 16
500 MW - FIVE STAGES 600 MW - THREE STAGES
• Less resistance for Stator Core cooling and optimised rotor, less pressure across compressor • Reduced compressor losses and hence higher efficiency
Optimisation of Compressor Stages
BHEL Haridwar
Electrical Machine Engineering 17
Core Insertion into Stator
BHEL Haridwar
Electrical Machine Engineering 18
Cooler Housing Frame houses vertical coolers and End Shield houses bearings , shaft seals etc.
Easier to handle and assemble at works/site.
TE End Shield in two parts
Cooler Housing Frame
End Shield
BHEL Haridwar
Electrical Machine Engineering 19
500 MW 600 MW
DOUBLE INDENT WEDGE
TRAPEZOIDAL SLOT SHAPE
SINGLE INDENT WEDGE - SIMPLIFICATION
PARALLEL SLOT - VARIETY REDUCTION
Rotor Slot & Wedge
BHEL Haridwar
Electrical Machine Engineering 20
500 MW - NINE SHAPES 600 MW - SHAPE SLOT
600 MW - SHAPE OVERHANG
Increased cooling duct size in 600 MW design Provides better cooling
Rotor Cooling Duct
BHEL Haridwar
Electrical Machine Engineering 21
Replaces earlier Circular coils with Simple design.Resulting in time Cycle reduction.
Rectangular Rotor End Winding
BHEL Haridwar
Electrical Machine Engineering 22
• Single flow Ring Type Shaft Seals • Simple construction and easy O & M
SINGLE FLOW - 600 MW DOUBLE FLOW - 500 MW
Seal Oil System
BHEL Haridwar
Electrical Machine Engineering 23
Parameter Unit 600 MW 500 MW Rated Voltage kV 21 21 Rated Current Amp 19407 16166 Hyd. Press. (g) Bar 5 3.5
P.F. - 0.85 0.85 Transportation
LxW mm 9875x3880 8830x4100
Stator Transportation
Weight
T 316 265
Technical Parameters
BHEL Haridwar
Electrical Machine Engineering 24
Paiton Phase II, Unit 5 Indonesia 1999
Paiton Phase II, Unit 6 Indonesia 1999
Hanfeng Unit 1 China 2000
Hanfeng Unit 2 China 2001
Iskenderun Unit 1 Turkey 2003
Iskenderun Unit 2 Turkey 2003
Collaborator’s Experience
BHEL Haridwar
Electrical Machine Engineering 25
THANK YOU
END
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