CONTENTS

Cover

Series Page

Title Page

Dedication

Preface

Acknowledgments

I: Theory, Construction, and Operation

Chapter 1: Principles of Operation of Synchronous Machines
1. 1.1 Introduction to Basic Notions on Electric Power
2. 1.2 Electrical–Mechanical Equivalence
3. 1.3 Alternating Current (ac)
4. 1.4 Three-Phase Circuits
5. 1.5 Basic Principles of Machine Operation
6. 1.6 The Synchronous Machine
7. 1.7 Basic Operation of the Synchronous Machine
Chapter 2: Generator Design and Construction
1. 2.1 Stator Core
2. 2.2 Stator Frame
3. 2.3 Flux and Armature Reaction
4. 2.4 Electromagnetics
5. 2.5 End-Region Effects and Flux Shielding
6. 2.6 Stator Core and Frame Forces
7. 2.7 Stator Windings
8. 2.8 Stator Winding Wedges
9. 2.9 End-Winding Support Systems
10. 2.10 Stator Terminal Connections
11. 2.11 Rotor Forging
12. 2.12 Rotor Winding
13. 2.13 Rotor Winding Slot Wedges
14. 2.14 Amortisseur (Damper) Winding
15. 2.15 Retaining Rings
16. 2.16 Bore Copper and Terminal Connectors
17. 2.17 Slip/Collector Rings and Brush Gear
18. 2.18 Rotor Couplings
19. 2.19 Rotor Turning Gear
20. 2.20 Bearings
21. 2.21 Air and Hydrogen Cooling
22. 2.22 Rotor Fans
23. 2.23 Hydrogen Containment
24. 2.24 Hydrogen Coolers
25. 2.25 Air Coolers
26. 2.26 Water-Cooled Rotors
27. References
Chapter 3: Generator Auxiliary Systems
1. 3.1 Lube-Oil System
2. 3.2 Hydrogen Cooling System
3. 3.3 Seal-Oil System
4. 3.4 Stator Cooling Water System
5. 3.5 Exciter Systems
Chapter 4: Operation and Control
1. 4.1 Basic Operating Parameters
2. 4.2 Operating Modes
3. 4.3 Machine Curves
4. 4.4 Special Operating Conditions
5. 4.5 Basic Operation Concepts
6. 4.6 System Considerations
7. 4.7 Grid-Induced Torsional Vibrations
8. 4.8 Excitation and Voltage Regulation
9. 4.9 Performance Curves
10. 4.10 Sample of Generator Operating Instructions
11. Main Generator Operating Instructions
12. References
Chapter 5: Monitoring and Diagnostics
1. 5.1 Generator Monitoring Philosophies
2. 5.2 Monitoring Versus Protection: Definition and Practice
3. 5.3 Extent of Monitoring Versus Cost and Benefits
4. 5.4 Simple Monitoring With Static High-Level Alarm Limits
5. 5.5 Dynamic Monitoring With Load-Varying Alarm Limits
6. 5.6 Artificial Intelligence Diagnostic Systems
7. 5.7 Monitoring a Single Parameter Versus a Multifunction Instrument
8. 5.8 Monitored Parameters
9. References
Chapter 6: Generator Protection
1. 6.1 Basic Protection Philosophy
2. 6.2 Generator Protective Functions
3. 6.3 Brief Description of Protective Functions
4. 6.4 Specialized Protection Schemes
5. 6.5 Tripping and Alarming Methods
6. References

II: Inspection, Maintenance, and Testing

Chapter 7: Inspection Practices and Methodology
1. 7.1 Site Preparation
2. 7.2 Experience and Training
3. 7.3 Safety Procedures
4. 7.4 Inspection Frequency
5. 7.5 Generator Accessibility
6. 7.6 Inspection Tools
7. 7.7 Inspection Forms
8. References
Chapter 8: Stator Inspection
1. 8.1 Stator Frame and Casing
2. 8.2 Stator Core
3. 8.3 Stator Windings
4. 8.4 Phase Connectors and Terminals
5. 8.5 Hydrogen Coolers
6. References
Chapter 9: Rotor Inspection
1. 9.1 Rotor Cleanliness
2. 9.2 Retaining Rings
3. 9.3 Fretting/Movement at Interference-Fit Surfaces of Wedges and Rings
4. 9.4 Centering (Balance) Rings
5. 9.5 Fan Rings or Hubs
6. 9.6 Fan Blades
7. 9.7 Bearings and Journals
8. 9.8 Balance Weights and Bolts
9. 9.9 End Wedges, Slot Wedges, and Damper Windings
10. 9.10 Other Wedges
11. 9.11 Windings: General
12. 9.12 Windings: Slot Region
13. 9.13 End Windings and Main Leads
14. 9.14 Collector Rings
15. 9.15 Collector Ring Insulation
16. 9.16 Bore Copper and Radial (Vertical) Terminal Stud Connectors
17. 9.17 Brush-Spring Pressure and General Condition
18. 9.18 Brush Rigging
19. 9.19 Shaft Voltage Discharge (Grounding) Brushes
20. 9.20 Rotor Winding Main Lead Hydrogen Sealing: Inner and Outer
21. 9.21 Circumferential Pole Slots (Body Flex Slots)
22. 9.22 Blocked Rotor Radial Vent Holes: Shifting of Winding and/or Insulation
23. 9.23 Couplings and Coupling Bolts
24. 9.24 Bearing Insulation
25. 9.25 Hydrogen Seals
26. 9.26 Rotor Body Zone Rings
27. 9.27 Rotor Removal
28. References
Chapter 10: Auxiliaries Inspection
1. 10.1 Lube-Oil System
2. 10.2 Hydrogen Cooling System
3. 10.3 Seal-Oil System
4. 10.4 Stator Cooling Water System
5. 10.5 Exciters
Chapter 11: Generator Maintenance Testing
1. 11.1 Stator Core Mechanical Tests
2. 11.2 Stator Core Electrical Tests
3. 11.3 Stator Winding Mechanical Tests
4. 11.4 Water-Cooled Stator Winding Tests
5. 11.5 Stator Winding Electrical Tests
6. 11.6 Rotor Mechanical Testing
7. 11.7 Rotor Electrical Testing
8. 11.8 Hydrogen Seals
9. 11.9 Bearings
10. 11.10 Thermal Sensitivity Testing and Analysis
11. 11.11 Heat-Run Testing
12. 11.12 Hydrogen Leak Detection
13. References
Chapter 12: Maintenance
1. 12.1 General Maintenance Philosophies
2. 12.2 Operational and Maintenance History
3. 12.3 Maintenance Intervals/Frequency
4. 12.4 Type of Maintenance
5. 12.5 Work Site Location
6. 12.6 Workforce
7. 12.7 Spare Parts
8. 12.8 Uprating
9. 12.9 Long-Term Storage and Mothballing
10. 12.10 Life Cycle Management (LCM)
11. 12.11 Single-Point Vulnerability (SPV) Analysis
12. References
Chapter 13: New Grid Codes
1. 13.1 New Grid Codes and Their Impact on Generators
2. 13.2 Regulatory Requirements for Turbo-Generators [1]
3. References

Index

End User License Agreement

List of Illustrations

Fig. 1.1

Fig. 1.2

Fig. 1.3

Fig. 1.4

Fig. 1.5

Fig. 1.6

Fig. 1.7

Fig. 1.8

Fig. 1.9

Fig. 1.10

Fig. 1.11

Fig. 1.12

Fig. 1.13

Fig. 1.14

Fig. 1.15

Fig. 1.16

Fig. 1.17

Fig. 1.18

Fig. 1.19

Fig. 1.20

Fig. 1.21

Fig. 1.22

Fig. 1.23

Fig. 1.24

Fig. 1.25

Fig. 1.26

Fig. 1.27

Fig. 1.28

Fig. 1.29

Fig. 1.30

Fig. 1.31

Fig. 1.32

Fig. 1.33

Fig. 1.34

Fig. 1.35

Fig. 1.36

Fig. 1.37

Fig. 1.38

Fig. 1.39

Fig. 1.40

Fig. 1.41

Fig. 1.42

Fig. 1.43

Fig. 1.44

Fig. 1.45

Fig. 1.46

Fig. 1.47

Fig. 1.48

Fig. 1.49

Fig. 1.50

Fig. 1.51

Fig. 2.1

Fig. 2.2

Fig. 2.3

Fig. 2.4

Fig. 2.5

Fig. 2.6

Fig. 2.7

Fig. 2.8

Fig. 2.9

Fig. 2.10

Fig. 2.11

Fig. 2.12

Fig. 2.13

Fig. 2.14

Fig. 2.15

Fig. 2.16

Fig. 2.17

Fig. 2.18

Fig. 2.19

Fig. 2.20

Fig. 2.21

Fig. 2.22

Fig. 2.23

Fig. 2.24

Fig. 2.25

Fig. 2.26

Fig. 2.27

Fig. 2.28

Fig. 2.29

Fig. 2.30

Fig. 2.31

Fig. 2.32

Fig. 2.33

Fig. 2.34

Fig. 2.35

Fig. 2.36

Fig. 2.37

Fig. 2.38

Fig. 2.39

Fig. 2.40

Fig. 2.41

Fig. 2.42

Fig. 2.43

Fig. 2.44

Fig. 2.45

Fig. 2.46

Fig. 2.47

Fig. 2.48

Fig. 2.49

Fig. 2.50

Fig. 2.51

Fig. 2.52

Fig. 2.53

Fig. 2.54

Fig. 2.55

Fig. 2.56

Fig. 2.57

Fig. 2.58

Fig. 2.59

Fig. 2.60

Fig. 2.61

Fig. 2.62

Fig. 2.63

Fig. 2.64

Fig. 2.65

Fig. 2.66

Fig. 2.67

Fig. 2.68

Fig. 2.69

Fig. 2.70

Fig. 2.71

Fig. 2.72

Fig. 2.73

Fig. 2.74

Fig. 2.75

Fig. 2.76

Fig. 2.77

Fig. 2.78

Fig. 2.79

Fig. 2.80

Fig. 2.81

Fig. 2.82

Fig. 2.83

Fig. 2.84

Fig. 2.85

Fig. 2.86

Fig. 2.87

Fig. 2.88

Fig. 2.89

Fig. 2.90

Fig. 2.91

Fig. 2.92

Fig. 2.93

Fig. 2.94

Fig. 2.95

Fig. 2.96

Fig. 2.97

Fig. 2.98

Fig. 2.99

Fig. 2.100

Fig. 2.101

Fig. 2.102

Fig. 2.103

Fig. 2.104

Fig. 2.105

Fig. 2.106

Fig. 2.107

Fig. 2.108

Fig. 2.109

Fig. 2.110

Fig. 2.111

Fig. 2.112

Fig. 2.113

Fig. 2.114

Fig. 2.115

Fig. 2.116

Fig. 2.117

Fig. 2.118

Fig. 2.119

Fig. 2.120

Fig. 2.121

Fig. 2.122

Fig. 2.123

Fig. 2.124

Fig. 2.125

Fig. 2.126

Fig. 2.127

Fig. 2.128

Fig. 2.129

Fig. 2.130

Fig. 2.131

Fig. 2.132

Fig. 2.133

Fig. 2.134

Fig. 2.135

Fig. 2.136

Fig. 2.137

Fig. 2.138

Fig. 2.139

Fig. 3.1

Fig. 3.2

Fig. 3.3

Fig. 3.4

Fig. 3.5

Fig. 3.6

Fig. 3.7

Fig. 3.8

Fig. 3.9

Fig. 3.10

Fig. 3.11

Fig. 3.12

Fig. 3.13

Fig. 3.14

Fig. 3.15

Fig. 3.16

Fig. 3.17

Fig. 3.18

Fig. 3.19

Fig. 3.20

Fig. 3.21

Fig. 3.22

Fig. 3.23

Fig. 3.24

Fig. 3.25

Fig. 3.26

Fig. 3.27

Fig. 3.28

Fig. 3.29

Fig. 3.30

Fig. 3.31

Fig. 3.32

Fig. 3.33

Fig. 3.34

Fig. 3.35

Fig. 3.36

Fig. 4.1

Fig. 4.2

Fig. 4.3

Fig. 4.4

Fig. 4.5

Fig. 4.6

Fig. 4.7

Fig. 4.8

Fig. 4.9

Fig. 4.10

Fig. 4.11

Fig. 4.12

Fig. 4.13

Fig. 4.14

Fig. 4.15

Fig. 4.16

Fig. 4.17

Fig. 4.18

Fig. 4.19

Fig. 4.20

Fig. 4.21

Fig. 4.22

Fig. 4.23

Fig. 4.24

Fig. 4.25

Fig. 4.26

Fig. 4.27

Fig. 4.28

Fig. 4.29

Fig. 4.30

Fig. 4.31

Fig. 4.32

Fig. 4.33

Fig. 4.34

Fig. 4.35

Fig. 4.36

Fig. 4.37

Fig. 4.38

Fig. 4.39

Fig. 4.40

Fig. 4.41

Fig. 4.42

Fig. 4.43

Fig. 4.44

Fig. 4.45

Fig. 4.46

Fig. 4.47

Fig. 4.48

Fig. 4.49

Fig. 4.50

Fig. 4.51

Fig. 4.52

Fig. 4.53

Fig. 4.54

Fig. 4.55

Fig. 4.56

Fig. 4.57

Fig. 4.58

Fig. 4.59

Fig. 4.60

Fig. 4.61

Fig. 4.62

Fig. 4.63

Fig. 4.64

Fig. 4.65

Fig. 4.66

Fig. 4.67

Fig. 4.68

Fig. 4.69

Fig. 4.70

Fig. 4.71

Fig. 4.72

Fig. 4.73

Fig. 4.74

Fig. 4.75

Fig. 4.76

Fig. 4.77

Fig. 4.78

Fig. 4.79

Fig. 4.80

Fig. 4.81

Fig. 4.82

Fig. 4.83

Fig. 4.84

Fig. 4.85

Fig. 4.86

Fig. 4.87

Fig. 4.88

Fig. 4.89

Fig. 4.90

Fig. 4.91

Fig. 4.92

Fig. 4.93

Fig. 4.94

Fig. 4.95

Fig. 4.96

Fig. 4.97

Fig. 4.98

Fig. 5.1

Fig. 5.2

Fig. 5.3

Fig. 5.4

Fig. 5.5

Fig. 5.6

Fig. 5.7

Fig. 5.8

Fig. 5.9

Fig. 5.10

Fig. 5.11

Fig. 5.12

Fig. 5.13

Fig. 5.14

Fig. 5.15

Fig. 5.16

Fig. 5.17

Fig. 5.18

Fig. 5.19

Fig. 5.20

Fig. 5.21

Fig. 5.22

Fig. 5.23

Fig. 5.24

Fig. 5.25

Fig. 5.26

Fig. 5.27

Fig. 5.28

Fig. 5.29

Fig. 5.30

Fig. 5.31

Fig. 5.32

Fig. 5.33

Fig. 5.34

Fig. 5.35

Fig. 5.36

Fig. 5.37

Fig. 5.38

Fig. 5.39

Fig. 5.40

Fig. 5.41

Fig. 5.42

Fig. 5.43

Fig. 5.44

Fig. 5.45

Fig. 5.46

Fig. 5.47

Fig. 5.48

Fig. 5.49

Fig. 5.50

Fig. 5.51

Fig. 5.52

Fig. 5.53

Fig. 5.54

Fig. 5.55

Fig. 5.56

Fig. 5.57

Fig. 5.58

Fig. 5.59

Fig. 5.60

Fig. 5.61

Fig. 5.62

Fig. 5.63

Fig. 5.64

Fig. 5.65

Fig. 5.66

Fig. 5.67

Fig. 5.68

Fig. 5.69

Fig. 5.70

Fig. 5.71

Fig. 5.72

Fig. 5.73

Fig. 6.1

Fig. 6.2

Fig. 6.3

Fig. 6.4

Fig. 6.5

Fig. 6.6

Fig. 6.7

Fig. 6.8

Fig. 6.9

Fig. 6.10

Fig. 6.11

Fig. 6.12

Fig. 6.13

Fig. 6.14

Fig. 6.15

Fig. 6.16

Fig. 6.17

Fig. 6.18

Fig. 6.19

Fig. 6.20

Fig. 6.21

Fig. 6.22

Fig. 6.23

Fig. 6.24

Fig. 6.25

Fig. 6.26

Fig. 6.27

Fig. 6.28

Fig. 6.29

Fig. 6.30

Fig. 6.31

Fig. 6.32

Fig. 6.33

Fig. 6.34

Fig. 6.35

Fig. 6.36

Fig. 6.37

Fig. 6.38

Fig. 6.39

Fig. 6.40

Fig. 6.41

Fig. 6.42

Fig. 6.43

Fig. 7.1

Fig. 7.2

Fig. 7.3

Fig. 7.4

Fig. 7.5

Fig. 7.6

Fig. 7.7

Fig. 7.8

Fig. 7.9

Fig. 7.10

Fig. 7.11

Fig. 7.12

Fig. 7.13

Fig. 7.14

Fig. 7.15

Fig. 7.16

Fig. 7.17

Fig. 7.18

Fig. 7.19

Fig. 7.20

Fig. 7.21

Fig. 7.22

Fig. 7.23

Fig. 7.24

Fig. 7.25

Fig. 7.26

Fig. 7.27

Fig. 7.28

Fig. 7.29

Fig. 7.30

Fig. 7.31

Fig. 7.32

Fig. 7.33

Fig. 7.34

Fig. 8.1

Fig. 8.2

Fig. 8.3

Fig. 8.4

Fig. 8.5

Fig. 8.6

Fig. 8.7

Fig. 8.8

Fig. 8.9

Fig. 8.10

Fig. 8.11

Fig. 8.12

Fig. 8.13

Fig. 8.14

Fig. 8.15

Fig. 8.16

Fig. 8.17

Fig. 8.18

Fig. 8.19

Fig. 8.20

Fig. 8.21

Fig. 8.22

Fig. 8.23

Fig. 8.24

Fig. 8.25

Fig. 8.26

Fig. 8.27

Fig. 8.28

Fig. 8.29

Fig. 8.30

Fig. 8.31

Fig. 8.32

Fig. 8.33

Fig. 8.34

Fig. 8.35

Fig. 8.36

Fig. 8.37

Fig. 8.38

Fig. 8.39

Fig. 8.40

Fig. 8.41

Fig. 8.42

Fig. 8.43

Fig. 8.44

Fig. 8.45

Fig. 8.46

Fig. 8.47

Fig. 8.48

Fig. 8.49

Fig. 8.50

Fig. 8.51

Fig. 8.52

Fig. 8.53

Fig. 8.54

Fig. 8.55

Fig. 8.56

Fig. 8.57

Fig. 8.58

Fig. 8.59

Fig. 8.60

Fig. 8.61

Fig. 8.62

Fig. 8.63

Fig. 8.64

Fig. 8.65

Fig. 8.66

Fig. 8.67

Fig. 8.68

Fig. 8.69

Fig. 8.70

Fig. 8.71

Fig. 8.72

Fig. 8.73

Fig. 8.74

Fig. 8.75

Fig. 8.76

Fig. 8.77

Fig. 8.78

Fig. 8.79

Fig. 8.80

Fig. 8.81

Fig. 8.82

Fig. 8.83

Fig. 8.84

Fig. 8.85

Fig. 8.86

Fig. 8.87

Fig. 8.88

Fig. 8.89

Fig. 8.90

Fig. 8.91

Fig. 8.92

Fig. 8.93

Fig. 8.94

Fig. 8.95

Fig. 8.96

Fig. 8.97

Fig. 8.98

Fig. 8.99

Fig. 8.100

Fig. 8.101

Fig. 8.102

Fig. 8.103

Fig. 8.104

Fig. 8.105

Fig. 8.106

Fig. 8.107

Fig. 8.108

Fig. 8.109

Fig. 8.110

Fig. 8.111

Fig. 8.112

Fig. 8.113

Fig. 8.114

Fig. 8.115

Fig. 8.116

Fig. 8.117

Fig. 8.118

Fig. 8.119

Fig. 8.120

Fig. 8.121

Fig. 8.122

Fig. 8.123

Fig. 8.124

Fig. 8.125

Fig. 8.126

Fig. 8.127

Fig. 8.128

Fig. 8.129

Fig. 8.130

Fig. 8.131

Fig. 8.132

Fig. 8.133

Fig. 8.134

Fig. 8.135

Fig. 8.136

Fig. 8.137

Fig. 8.138

Fig. 8.139

Fig. 8.140

Fig. 8.141

Fig. 8.142

Fig. 8.143

Fig. 8.144

Fig. 8.145

Fig. 8.146

Fig. 8.147

Fig. 8.148

Fig. 8.149

Fig. 8.150

Fig. 8.151

Fig. 8.152

Fig. 8.153

Fig. 8.154

Fig. 9.1

Fig. 9.2

Fig. 9.3

Fig. 9.4

Fig. 9.5

Fig. 9.6

Fig. 9.7

Fig. 9.8

Fig. 9.9

Fig. 9.10

Fig. 9.11

Fig. 9.12

Fig. 9.13

Fig. 9.14

Fig. 9.15

Fig. 9.16

Fig. 9.17

Fig. 9.18

Fig. 9.19

Fig. 9.20

Fig. 9.21

Fig. 9.22

Fig. 9.23

Fig. 9.24

Fig. 9.25

Fig. 9.26

Fig. 9.27

Fig. 9.28

Fig. 9.29

Fig. 9.30

Fig. 9.31

Fig. 9.32

Fig. 9.33

Fig. 9.34

Fig. 9.35

Fig. 9.36

Fig. 9.37

Fig. 9.38

Fig. 9.39

Fig. 9.40

Fig. 9.41

Fig. 9.42

Fig. 9.43

Fig. 9.44

Fig. 9.45

Fig. 9.46

Fig. 9.47

Fig. 9.48

Fig. 9.49

Fig. 9.50

Fig. 9.51

Fig. 9.52

Fig. 9.53

Fig. 9.54

Fig. 9.55

Fig. 9.56

Fig. 9.57

Fig. 9.58

Fig. 9.59

Fig. 9.60

Fig. 9.61

Fig. 9.62

Fig. 9.63

Fig. 9.64

Fig. 9.65

Fig. 9.66

Fig. 9.67

Fig. 9.68

Fig. 9.69

Fig. 9.70

Fig. 9.71

Fig. 9.72

Fig. 9.73

Fig. 9.74

Fig. 9.75

Fig. 9.76

Fig. 9.77

Fig. 9.78

Fig. 9.79

Fig. 9.80

Fig. 9.81

Fig. 9.82

Fig. 9.83

Fig. 9.84

Fig. 9.85

Fig. 9.86

Fig. 9.87

Fig. 9.88

Fig. 9.89

Fig. 9.90

Fig. 9.91

Fig. 9.92

Fig. 9.93

Fig. 9.94

Fig. 9.95

Fig. 9.96

Fig. 9.97

Fig. 9.98

Fig. 9.99

Fig. 9.100

Fig. 9.101

Fig. 9.102

Fig. 9.103

Fig. 9.104

Fig. 9.105

Fig. 9.106

Fig. 9.107

Fig. 9.108

Fig. 9.109

Fig. 9.110

Fig. 9.111

Fig. 9.112

Fig. 9.113

Fig. 9.114

Fig. 9.115

Fig. 9.116

Fig. 9.117

Fig. 9.118

Fig. 9.119

Fig. 9.120

Fig. 9.121

Fig. 9.122

Fig. 9.123

Fig. 9.124

Fig. 9.125

Fig. 9.126

Fig. 9.127

Fig. 9.128

Fig. 9.129

Fig. 9.130

Fig. 9.131

Fig. 9.132

Fig. 9.133

Fig. 9.134

Fig. 9.135

Fig. 9.136

Fig. 9.137

Fig. 9.138

Fig. 9.139

Fig. 9.140

Fig. 9.141

Fig. 9.142

Fig. 9.143

Fig. 9.144

Fig. 9.145

Fig. 9.146

Fig. 9.147

Fig. 9.148

Fig. 9.149

Fig. 9.150

Fig. 9.151

Fig. 9.152

Fig. 9.153

Fig. 9.154

Fig. 9.155

Fig. 9.156

Fig. 9.157

Fig. 9.158

Fig. 9.159

Fig. 9.160

Fig. 9.161

Fig. 9.162

Fig. 9.163

Fig. 9.164

Fig. 9.165

Fig. 9.166

Fig. 9.167

Fig. 9.168

Fig. 9.169

Fig. 9.170

Fig. 9.171

Fig. 9.172

Fig. 9.173

Fig. 9.174

Fig. 9.175

Fig. 9.176

Fig. 9.177

Fig. 9.178

Fig. 9.179

Fig. 9.180

Fig. 9.181

Fig. 9.182

Fig. 9.183

Fig. 9.184

Fig. 9.185

Fig. 9.186

Fig. 9.187

Fig. 9.188

Fig. 9.189

Fig. 9.190

Fig. 9.191

Fig. 9.192

Fig. 9.193

Fig. 9.194

Fig. 9.195

Fig. 9.196

Fig. 9.197

Fig. 9.198

Fig. 9.199

Fig. 10.1

Fig. 10.2

Fig. 10.3

Fig. 10.4

Fig. 10.5

Fig. 10.6

Fig. 11.1

Fig. 11.2

Fig. 11.3

Fig. 11.4

Fig. 11.5

Fig. 11.6

Fig. 11.7

Fig. 11.8

Fig. 11.9

Fig. 11.10

Fig. 11.11

Fig. 11.12

Fig. 11.13

Fig. 11.14

Fig. 11.15

Fig. 11.16

Fig. 11.17

Fig. 11.18

Fig. 11.19

Fig. 11.20

Fig. 11.21

Fig. 11.22

Fig. 11.23

Fig. 11.24

Fig. 11.25

Fig. 11.26

Fig. 11.27

Fig. 11.28

Fig. 11.29

Fig. 11.30

Fig. 11.31

Fig. 11.32

Fig. 11.33

Fig. 11.34

Fig. 11.35

Fig. 11.36

Fig. 11.37

Fig. 11.38

Fig. 11.39

Fig. 11.40

Fig. 11.41

Fig. 11.42

Fig. 11.43

Fig. 11.44

Fig. 11.45

Fig. 11.46

Fig. 11.47

Fig. 11.48

Fig. 11.49

Fig. 11.50

Fig. 11.51

Fig. 11.52

Fig. 11.53

Fig. 11.54

Fig. 11.55

Fig. 11.56

Fig. 11.57

Fig. 11.58

Fig. 11.59

Fig. 11.60

Fig. 11.61

Fig. 11.62

Fig. 11.63

Fig. 11.64

Fig. 11.65

Fig. 11.66

Fig. 11.67

Fig. 11.68

Fig. 11.69

Fig. 11.70

Fig. 11.71

Fig. 11.72

Fig. 11.73

Fig. 11.74

Fig. 11.75

Fig. 11.76

Fig. 11.77

Fig. 11.78

Fig. 11.79

Fig. 11.80

Fig. 11.81

Fig. 11.82

Fig. 11.83

Fig. 11.84

Fig. 11.85

Fig. 11.86

Fig. 11.87

Fig. 11.88

Fig. 11.89

Fig. 11.90

Fig. 11.91

Fig. 11.92

Fig. 11.93

Fig. 11.94

Fig. 11.95

Fig. 11.96

Fig. 11.97

Fig. 11.98

Fig. 11.99

Fig. 11.100

Fig. 11.101

Fig. 11.102

Fig. 11.103

Fig. 11.104

Fig. 12.1

Fig. 12.2

Fig. 12.3

Fig. 12.4

Fig. 12.5

Fig. 12.6

Fig. 12.7

Fig. 12.8

Fig. 12.9

Fig. 12.10

Fig 12.11

Fig. 12.12

Fig. 12.13

Fig. 12.14

Fig. 12.15

Fig. 12.16

Fig. 13.1

Fig. 13.2

Fig. 13.3

Fig. 13.4

Fig. 13.5

Fig. 13.6

Fig. 13.7

Fig. 13.8

Preface

It is not uncommon for a large utility to have units of disparate size, origin, and vintage in its fleet of generators. Among its dozens of generators, there might still be some from the 1950s or 1960s and some with their original asphalt or thermoplastic windings. These, and later units, may be operating with or without magnetic retaining rings. Some may have thermosetting epoxy-mica windings of all sorts—with or without asbestos. Machine types will vary from air-cooled, hydrogen-cooled stators with water-cooled windings to some with water-cooled rotors. The prime mover for any machine may also be very different, such as steam-driven or combustion-driven. And the excitation systems will also vary in the form of self-excited or static excitation and so on. The list is endless for the different machine types and configurations one will find in the power industry, but it does not end there. There is also diversity in grid systems around the world. One will find two basic operating frequencies at 50 and 60 Hz, depending on which continent or country you are in. And therefore, machines built by Western, Asian, and Eastern European manufacturers are done so to different standards. This is what you may find with some of the independent, deregulated power producers around the world. In addition, some will be building new plants and/or have purchased entire fleets of older units in several countries around the globe.

The reasons why one may find so many “old” units still in operation are not difficult to discern. First of all, a typical generator is made with an intent to last no less than 30 years, or more. Second, replacing an operating unit is very capital intensive, and thus done only when a catastrophic failure has occurred, or some other major failure of the machine that renders continuous operation not economically viable. Third, although expected to last 30 years, large turbo-generators are known to have their lives extended far beyond that, if well maintained and operated. Sometimes that also requires replacing a major component, such as the armature winding and/or a rotor winding (or the entire stator or rotor!). Significant changes in design tend to occur every few years, for different components. For instance, a history of the insulation systems encountered in generators shows that every few years there is some big change resulting in increased ratings. These changes typically derive from the adoption of new materials such as the change from magnetic to nonmagnetic material for retaining rings. Not all changes are always positive. Some new designs end up being reversed or revised after experience unmasks significant holes in them.

There are countless scraps of information about the operation, maintenance, and troubleshooting of large turbo-generators in many publications. All vendors at one stage or another have produced and published interesting literature about the operation of their generators. In particular, the technical information letters put out by some manufacturers (called by different names by different vendors) offer a wealth of detailed O&M topics. Institutions such as EPRI in the United States, CIGRE, IEC, ANSI, IEEE, and other national standards cover various aspects of the operation and maintenance of generators in general, but no specifics that may help troubleshoot a particular unit. It is difficult to obtain from those sources a condensed and operational set of insights useful to the solution of a given problem with a specific machine. It is no wonder then that with so many dissimilar units in operation and such a variegated experience, we are often forced to call the “experts,” who tend to be folks almost as old as the oldest units in operation. These are individuals who have crawled, inspected, tested, and maintained many diverse generators over the years. In doing so, they have retained knowledge about the different design, material, and manufacturing characteristics, typical problems, and most effective solutions. This type of expertise cannot be learned in a classroom.

Unfortunately, not every company retains an individual with the breadth and depth of expertise required for troubleshooting all its units. In fact, with the advent of deregulation, many small nonutility (third-party) power producers operate small fleets of generators without the benefit of in-house expertise. In lieu of that, they depend heavily on the OEMs and independent consultants. Large utilities in many places have also seen their expertise dissipate, not to a small extent because of a refocus of management priorities. All these developments are occurring at the same time that these units are called to operate in a more onerous environment. Economic dispatch in a deregulated or semideregulated world results in an increased use of double-shifting and load-cycling.

Some effort has been made over the years to capture the expert's knowledge and make it readily available to any operator. This effort took the form of expert systems. However, adaptation of these computer programs to the many different types of generators and associated equipment in existence has proved to be the Achilles tendon of this technology.

This book is designed to partially fill the gap by offering a comprehensive view of the many issues related to the operation, inspection, maintenance, and troubleshooting of large turbine generators. The contents of this third edition have been significantly enhanced and many new additional topics included. All of the information in the book is the result of many years of combined hands-on experience of the authors. It was written with the machine's operator and inspector in mind, as well as providing a guide to uprating and life enhancement of large generators. Although not designed to provide a step-by-step guide for the troubleshooting of large generators, it serves as a valuable source of information that may prove to be useful during troubleshooting activities. The topics covered are also cross-referenced to other sources. Many such references are included to facilitate those readers so interested to enlarge their knowledge on a specific issue under discussion. For the most part, detailed theoretical equations have been left out, as there are several exceptionally good books on the theory of operation of synchronous machines. Those readers who so desire can readily access those books. Several references are cited. This book, however, is about the practical aspects that characterize the design, operation, and maintenance of large turbine-driven generators and a significant number of practical calculations used commonly in maintenance and testing situations have been included.

Chapter 1 (Principles of Operation of Synchronous Machines) provides a basis of theory for electricity and electromagnetism upon which the machines covered in this book are based. In addition, the fundamentals of synchronous machine construction and operation are also discussed. This is for the benefit of generator operators who have a mechanics background and are inclined to attain a modicum of proficiency in understanding the basic principles of operation of the generator. It also comes handy for those professors who would like to adopt this book as a reference source for a course on large rotating electric machinery.

Chapter 2 (Generator Design and Construction) and Chapter 3 (Generator Auxiliary Systems) contain a very detailed and informative description of all the components found in a typical generator and its associated auxiliary systems. Described herein are the functions that the components perform, as well as all relevant design and operational constraints. Some additional insights into design methods and calculations are also provided.

Chapter 4 (Operation and Control) introduces the layperson to the many operational variables that describe a generator. Most generator–grid interaction issues and their effects on the machine components and operation are covered in great detail.

Chapter 5 (Monitoring and Diagnostics) and Chapter 6 (Generator Protection) serve to introduce all aspects related to the online monitoring and the protection of a large turbo-generator. Although not intended to serve as a guideline for designing and setting the protection systems of a generator, they provide a wealth of background information and pointers to additional literature.

Chapter 7 (Inspection Practices and Methodology) leads off the second part of the book with a look at preparing for a hands-on inspection of large generators. The chapter discusses the issues of concern for safety of both personnel and the equipment as well the types of tools and approaches used in inspecting large generators. This chapter also contains a collection of most inspection forms typically used for inspecting turbo-generators. These forms are very useful and can be readily adapted to any machine and plant.

Chapter 8 (Stator Inspection), Chapter 9 (Rotor Inspection), and Chapter 10 (Auxiliaries Inspection) constitute the core of this book. They describe all components presented in Chapters 2 and 3, but within the context of their behavior under real operational constraints, modes of failure, and typical troubleshooting activities. These chapters provide detailed information on what to look for and how to recognize problems in the machine during inspection. Chapters 8 and 9 also contain some basic formulas and procedures for some of the various activities that occur during inspection, maintenance, and testing of large generators.

Chapter 11 (Generator Maintenance Testing) contains a comprehensive summary of the many techniques used to test the various components and systems comprising a generator. The purpose of the descriptions is not to serve as a guide to performing the tests—There are well-established guides and standards for that. Rather, they are intended to illustrate the palette of possible tests to choose from. Provided as well is a succinct explanation of the character of each test and explanations of how they are carried out.

Chapter 12 (Maintenance) is included to provide some perspective to the reader on the many choices and approaches that can be taken in generator and auxiliary systems maintenance. Often there are difficult decisions on how far to take maintenance. In some cases only basic maintenance may be required, and on other occasions it may be appropriate to carry out extensive rehabilitation of existing equipment or even replacement of components. This chapter discusses some of the issues that need to be considered when deciding on what, how much, and where to do it. Along with the regular maintenance aspects, other important issues like uprating and long-term storage are also addressed.

Chapter 13 (New Grid Codes) is altogether a new chapter in the book. It deals with the ongoing changes to the regulations affecting generation components of grids in developed countries, as well as current work looking into how these regulations and changing grids may require changes into the standards controlling turbo-generator design, construction, and application.

Since the publishing of the second edition, the printing of books with color figures, graphs, and even fonts has seen a giant leap forward. It is not uncommon now for technical books to have most of their graphics printed in color. And so, the IEEE Press and the publishers of this book have kindly agreed to print the photos and art included in this new edition in color. Photos, graphs, and art in color make a drastic improvement over black and white for a technical book like this one, where the maxim “a picture is worth a thousand words” really applies.

The contents have been updated and enlarged based on additional experience acquired by the authors over the last 10 years, as well as generous feedback from many colleagues. Every chapter has been rejuvenated. Subjects covered in the previous editions are expanded with some additional details, and new topics that we felt were left out from the earlier editions have been added.

In the same spirit as with the previous editions, the authors strived with this new edition to maintain the essential character of this book, as one that avoids deep theoretical discourse, but rather focuses on the practical aspects of the design, construction, testing, and operation of large turbo-generators. The feedback to the authors from countless readers of the previous editions clearly indicates that this approach has been the proper one.

We hope that this book will be useful not only to the operator in the power plant but also to the design engineer and the systems operations engineer. We have provided a wealth of information obtained in the field about the behavior of such machines, including typical problems and conditions of operation. The book should also be useful to the student of electrical rotating machines as a complementary reference to the books on machine's theory.

Although we have tried our best to cover each topic as comprehensively as possible, the book should not be seen as a guide to troubleshooting. In each case a real problem is approached, a whole number of very specific issues only relevant to that very unique machine come into play. These can never be anticipated or known and thus described in a book. Thus, we recommend the use of this book as a general reference source, but the reader will always obtain adequate on-the-spot expertise when approaching a particular problem.

We remain intent on updating the contents of this book from time to time, from our own experience as well as from that of others. Therefore, we would welcome from the readers their comments, which they can submit to the publisher, for incorporation in future editions.

Geoff Klempner

Isidor Kerszenbaum

Toronto, Ontario, Canada

Irvine, California

Giancarlo Fortino	Andreas Molisch	Linda Shafer
David Alan Grier	Saeid Nahavandi	Mohammad Shahidehpour
Donald Heirman	Ray Perez	Sarah Spurgeon
Xiaoou Li	Jeffrey Reed	Ahmet Murat Tekalp

Handbook of Large Turbo-Generator Operation and Maintenance

Preface

Acknowledgments

I
Theory, Construction, and Operation