electrical generator course geol-tar500l4r r2 print

7/30/2019 Electrical Generator Course GEOL-TAR500L4R r2 Print

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ELECTRIC GENERATORCOURSE

IOSU CENDOYA - PRODUCT TECHNICAL MANAGER

16TH NOVEMBER 2010

G8XR - TAR500L4R

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9:15-11:00 Electrical designThermal designInsulationManufacturing process

11:00-11:15 Break for coffee11:15-13:00 Auxiliary elements

Preventive maintenanceElectrical tests

13:00-14:30 Lunch14:30-17:00 Practice on the generator


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INDAR INDAR ELECTRIC S. L. designs

and manufactures rotative electricmachines since 1940

The company is located inBeasain (Gipuzkoa)

Product Engines

Synchronous Asynchronous Direct current

Generators Synchronous Asynchronous Wind power (DFIM) Direct current

Activity fields Energy

Wind power Hydroelectric Cogeneration and thermal

Industry Syderurgy and Metallurgy Various industries

Naval Propulsion Various actuating systems Generation Submersible

Railway Traction Generation

Infrastructures Pump Desalination

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ELECTRICAL DESIGN



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General Concepts

Power

Line Current

Line Voltage

DeltaStar Connection

Connections in a three-phase system

Vf Vll 3

IllVllP 3

Vf Vll

IllVllP 3

If Ill If Ill 3

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General Concepts

Magnetic field created by a wire coveredby current

X

Z

YI

H


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General Concepts Theorem of Ferraris:

A multiple phase winding of p pole pairsand covered by multiple phase balancedcurrents, whose frecuency is produces pfictitious pole pairs moving with /p speedalong the winding without suffering any

modification

Rotating magnetic field

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General Concepts

Synchronous Permanent magnets Wound rotor

Asynchronous Squirrel Cage Doubly fed (DFIM) Rotor variable resistance

Wind Power Generators


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Synchronous of magnets

Advantages High performance Low maintenance

Disadvantages Full converter, moreexpensive converter

Connection diagram

Asynchronous of cage

Advantages The cheapest Low maintenance

Disadvantages Fixed speed Constant reactiveconsumption

Connection diagram

Asynchronous of wound rotor

Advantages Variable speed Moderate price converter

Disadvantages Maintenance

Connection diagram

G3~ PWM

NetG3~

Net G3~

PWM

Net

General ConceptsWind Power Generators

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DIMENSIONING OF THEMACHINE

The volume of the machine is proportional tothe torque

D2*L T

T=P/ w

When fixing the power, if there are more poles,the machine is slower as well as bigger

p f

ns.60

s

s

nnn

s


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GENERATED POWER CURVEPartial load Full load

Disconnection

Connection

Wind speed m/s

E l e c t r i c a l p o w e r k W

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Losses in a generator

MechanicalPower

ElectricalPower

MechanicalLosses

Lossesin stator copper

Iron losses

Lossesin rotor copper

AdditionalLosses


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Losses in a generator Mechanical losses

Bearings Air movement

Steel losses Hysteresis losses Joule losses due to the Foucault currents

Stator copper losses Rotor copper losses

Additional losses Losses due to the current displacement Losses in the parts Various losses

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DFIM: Doubly Fed InductionMachine

Doubly Fed Induction Machine Doubly Fed Asynchronous Generator


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DFIM: Double Fed InductionMachine

Stator is directly connected to main Stator creates a magnetic field, which rotates with

the synchronous speed

Rotor is connected to a voltage inverter variable with frequency Magnetic field created by the rotor rotates with

respect to the rotor with variable speed

Both magnetic fields must rotate with the samespeed

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DFIM: Double Fed InductionMachine

Working with oversynchronous speed

Working with undersynchronous speedsynchronous

rotor rotor field referred to rotor

synchronous

rotor

rotor field referred to rotor


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Doubly-Fed Asynchronous Generator Equivalent Circuit

Rotor parameters referred to stator

V2/s

/s /s

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Power Distribution in a Wind Power Generator

slippagePPP

PP

stator slippage

slippagetotalrotor

slippagetotal

stator

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When the slippage is negative (oversynchronous speed)the rotor generates power

When the slippage is positive (undersynchronous speed)the rotor consumes power


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Doubly-fed Asynchronous Generator Speed-Torque curve

Par en funcin del deslizamiento

-60000

-40000

-20000

0

20000

40000

60000

-1-0,8-0,6-0,4-0,200,20,40,60,81

Deslizamiento

P a r [ N m ]

T o r q u e

( N m

)

Slippage

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PROTECTION DEGREE Design type IM B3: horizontal machine, floor mounted

with smooth shaft

Machine Protection factor IP54: protected against dust and splashing

water

Ring body Protection factor IP23: rainproof and protected against

penetration of solid bodies larger than 12 mm

Connection box Protection factor IP55.


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THERMAL DESIGN


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COOLING: LOSSES Losses

Pcu = I 2.R (Rotor & Stator) Pfe = Hysteresis and Foucault (Rotor & Stator) Pmec

Pcool = Electrofans & fans Pfr = Bearings, brushes, aerodynamic resistance

Materials Copper Magnetic plate Insulations Bearings Brushes


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TYPES OF INSULATIONS

>$$$$SPECIALC

>>$$$180H

>>>$$155F

>>>>$135B

MACHINESIZE

INSULATIONPRICE

MAX Temp.THERMICCLASS

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CONDUCTION CONVECTION- RADIATION

Conduction

Convection

Radiation

..s

Ak Q

.. AQ

).( 404 eQ


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DESIGN FACTORS

Ventilation type Temperature of the cool focus Insulation class Height

Different operation points Various

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Ventilation

0

200

400

600

800

1000

1200

1400

0 0,5 1 1,5 2 2,5 3 3,5

m3 /s

P a


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Heating of a machine

Curve Heating stabilization

Types of performance: S1

Cool focus temperature Measured thermal difference: it only

depends on the losses

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Power and Speed Curve

0,00

200,00

400,00

600,00

800,00

1000,00

1200,00

1400,00

1600,00

1800,00

2000,00

80000 85000 90000 95000 100000 105000 110000 115000 120000

Ser ie1 Seri e2 Ser ie3 Ser ie4 Ser ie5


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Temperature Curve Series 1 U Winding Series 2 Outside air inlet temperature

(generator feeding) Series 3 Outside air outlet temperature Series 4 - Inside air inlet temperature Series 5 Inside air outlet temperature

0,00

20,00

40,00

60,00

80,00

100,00

120,00

80000 85000 90000 95000 100000 105000 110000 115000 120000

Seri e1 Ser ie2 Seri e3 Ser ie4 Ser ie5

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TYPES OF COOLING Machine

Open Closed

Ventilation Electroventilated

Autoventilated Type of Cooling

Ribbed housing Heat exchanger Water Jacket

Cooler Air-air Air-water


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SECTION OF G5XR-NCR450L4R

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SECTION OF G8XR-TAR500L4R


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PQTV CURVESConnection DELTAFrecuency 50 [Hz]Speed 1680 [rpm]

Ambient temperature 50 [C]

Voltage 621 [ V] V oltage 655 [ V] Volt age 690 [V]Max. Pow. 2040 [ kW ] M ax . P ow . 2040 [ kW ] M ax . P ow . 2040 [kW]

Pnet Qnet Cos Pnet Qnet Cos Pne t Qnet Cos [kW] [kVAr] [-] [kW] [kVAr] [-] [kW] [kVAr] [-]

50 -670 0,07 50 -670 0,072040 -670 0,95 2040 -670 0,95

2040 0 1,00 2040 0 1,00 2040 0 1,002040 670 0,95 2040 670 0,95

50 670 0,07 50 670 0,07

Voltage 725 [ V] V oltage 759 [V]Max. Pow. 2040 [ kW ] M ax . P ow . 2040 [kW]

Pnet Qnet Cos Pnet Qnet Cos

[kW ] [kVAr] [-] [kW ] [kVAr] [-]50 -670 0,07 50 -670 0,07

2040 -670 0,95 2040 -670 0,952040 0 1,00 2040 0 1,002040 670 0,95 2040 670 0,95

50 670 0,07 50 670 0,07

0,95 UNDEREXCITED Q < 00,95 OVEREXCITED Q > 0

Graph P-Q

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

-800 -600 -400 -200 0 200 400 600 800

Qnet [kVAr]

Pnet[kW]

621 [V] 655 [V] 690 [V]725 [V] 759 [V]

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MAXIMUM TEMPERATURES ANDINTENSITY LIMITS

165Ttrip[C]160Talarm[C]

10----10----s th (min)

1775----1775----Is th (T AMB = 50C)

1775----1775----Isth (T AMB = 0C)

1950----1950----Max_Is th

10 ----10----r th (min)

760----760----Ir th (T AMB = 50C)

760----760----Ir th (T AMB = 0C)

835----835----Max_Ir th

11934190787,0452360XM (m /Equiv. Star)

4328112628835898103737RM (m /Equiv. Star)

25,9780,920,63361,9X2' (m /Equiv. Star)

1,785,311,795,39R2' (m /Equiv. Star)27,6786,122,20066,6X1 (m /Equiv. Star)

1,644,931,644.93R1 (m /Equiv. Star)

422105729128VNET+10%

34195533115VNETIS (A/Line)

1833106118241061ER (V/LL)

DeltaStar DeltaStar VNET = 690V

60 Hz50 HzT WINDING = 115 c

TAR500L4R


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INSULATION


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INSULATION FUNCTION It avoids passing the current between bodies

subjected to different voltage levels.


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TYPES OF INSULATIONS EARTH INSULATION BETWEEN PHASES BETWEEN TURNS

BETWEEN PLATES

BEARINGS

Shortcircuit

Hot points

Current passing

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TYPES OF INSULATIONS


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REQUESTS MECHANICAL THERMAL ELECTRICAL ENVIRONMENTAL

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Partial Discharges E=V/d (KV/mm) Air-breaking voltage= 3 kV/mm Breaking voltage of a generic insulation=300 kV/mm

Insulation lifetime = 20.000h according to the classtheory:

102*000.20)(

class

lifetime

C C K amb 15050100 max

000.20*82*000.202*000.20)150( 310150180

lifetime

yearslifetime 20)150(


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TYPES OF WINDINGS TYPES OF WINDINGS

STAR-DELTA

TYPES OF CONNECTION BOXES 3 ACCESIBLE TERMINALS 6 ACCESIBLE TERMINALS

NUMBER OF PARALLELS

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R R R

U V WU1

U2

R

V1

V2

R

W1

W2

R

WINDING DIAGRAMS

R

RR

U

WV


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ELECTRIAL TESTS Insulation resistance Dielectric strength Wave comparator Winding resistance

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JAVIER DOMINGUEZ SERVICE ASSISTANCE TECHNICIAN

16TH NOVEMBER 2010

G8XR - TAR500L4R


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PT100 Measure the temperature Place importance Protection element

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PT100


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PT100

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PT100


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PT100

50

PT100


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ENCODER

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INDUCTIVE SENSOR

MEASURE THE SHAFT SPEED REDUNDANT SISTEM IT WORKS AGAINST WORKS A

DENTED WHEEL


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ELECTROFANS

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ELECTROFANS


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HEATER RESISTANCE

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GENERATOR COURSE

PREVENTIVE MAINTENANCE


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Recommended Maintenance

Program

Re-grease bearings as indicated inbearing plate.

Re-greaseBearings

Condition.Visual inspectionBrush gear pressuremechanism

Condition of cables, color,insulation.

Visual inspectionBrush connectioncables

Alignment. Operation of microswitches.

Visual inspectionBrush holders

Check contact surface for uniformity and absence of severescratching. Check for uniform wear on all the brushes.

Visual inspectionBrushes

Condition and cleaning if necessary.

Visual inspectionGrid (external fan, ringcowl)

Test insulation resistance.TestStator and Rotor insulation

Check rings for proper condition.CleaningRing unit

See Tightening Torques drawing.Check tightnessNuts and bolts

Operation.CheckRoller Bearings

6 months

ObservationsActionElementMaintenanceInterval

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Condition, leakage.Visual InspectionSeals (connection boxes,cooler box, etc.)

Operation.CheckElectric-fans

Wear, roundness.TestSlip rings

Change of brushes andcheck brush gear pressuremechanism.

ReplacementBrushes

General condition, painting,earth connection.CheckMachine

Condition, terminals, wiringconnection.CheckConnection box

Operation, alignment,condition, tighteningtorques.

CheckEncoder

Operation.CheckHeater Resistors

Resistance.TestPT-100 elements (winding,bearing, air ring)

Vibration, general condition,insulation resistance, extranoise.

TestBearings

12 months

ObservationsActionElementMaintenanceInterval


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General Recommendation of the

Typical Spare Parts

2 pcsBearing

1 pcsRe-greasing cartridges9+1+1 pcBrush holders18+2+1 pcsBrushes 2+1 pcSpace heaters

4 pcsSeals (connection boxes,cooler box, etc)

1 pcEncoder

3 pcsElectric fansAmountSpare parts

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If metallic tapping is heard, the bearing must be replaced.

Vibration factors: Damaged bearings. Alignment of the generator. Loose the fixing points of the generator.

Vibrations transmitted from the coupling, gear box togenerator DE.

Take necessary actions to avoid this vibration sources.

Measure insulation resistance between shaft and frame. Low insulation is a signal of future bearing failure, due to current

passage (eddy or parasite currents).

Bearings


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Re-greasing of Bearings Re-greasing is essential to ensure a good

working operation.

Use the grease type indicated in the bearingnameplate.

A MIXTURE OF GREASES WITH DIFFERENTPROPERTIES MUST NOT BE USED.

Check lubrication channel is open and full of grease, dismount lubrication nozzle.

Re-grease as indicated on the bearing nameplate.

Lubrication nozzle in the D.E. and N.D.E. sidesto connect the grease pump.

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Bolt Tightness

The bolts to be checked and their corresponding tightening torque are listed inthe tightening torque drawing.

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Cleaning of the Ring Unit The sliding surfaces of the slip rings and

brushes should be kept smooth and clean.

Brush wear generates conductive coal dustthat generates conducting bridges over theinsulation surfaces.

Electric discharges may take place betweenslip rings or to earth that can lead to failure.

The contact surface of slip rings forms apatina, or skin, together with the brushes. It isa benefit to brush operation.

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Take the brushes out of their lodgings.

Use a small brush to collect the carbon dustreleased by the brushes.


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Use the vacuum cleaner to suck in all thedust.

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Spray the dielectric solvent (take the safetymeasures indicated in the security sheet of theproduct) all over the ring.

Allow all components of the ring unit to drycompletely (approx. 5 min.).

Use a clean cloth to remove any liquid or dirtdeposited in the ring unit.


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Use the vacuum cleaner to suck in all the dust.

NOTE: Measure the insulation before and after the cleaning.

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Replacement of Brushes

The brushes wear due to the friction with theslip ring.

6 months estimated lifetime between the twomarks.

NECESSARY CHANGE 19mm

RECOMMENDED CHANGE 24mm


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Removal of brushes:

Undo the brush fixing screw. Lift the brush-holder pressure mechanism. Take the brush out of its housing of the brush-

holder. Repeat this action for all the brushes.

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Installation of brushes: Insert a new brush. Tighten the brush fixing screw. Put the brush into the housing. After mounting the two brushes into each brush-

holder, put a piece of sandpaper (No. 2) on the ring,

with the abrasive side up. Apply the brush-holder pressure mechanism. Move the sandpaper along the ring curve to ensure

correct bedding of the brush on the ring. Repeat this process for all paired brushes of each

brush-holder.


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Relation of Electrical Tests

Electric (ohmic) resistance.

Insulation resistance.

Surge test.

Withstand Voltage test.

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Electrical Resistance The winding ohmic resistance is measured

by a miliohmeter. In case of short-circuit phase to phase, a

local material destruction is produced whichresults on an open circuit.


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75

Insulation Resistance A DC voltage is applied. Submit the insulation to a voltage difference. Current leakages to earth or phase to phase

are measured. Detects short circuits of high magnitude,

winding contamination, humidity,

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Surge Test Apply a pulse of voltage. Introduce a voltage pulse through the beginning

of a winding and measure the reaction of thewinding to this pulse.

The frequency and amplitude of the inducedtension depends on the L and C of the winding.

Depends on the number of turns of a windingand the type of iron core on which it is wound.

It compares the voltages produced by equalwindings.


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Withstand Voltage Test Applies a high voltage ((2 * U N) + 1000). Detects initial failures (fabrication). The IEC standards forces to carry out to

every machine in manufacturing process. Partially destructive. For this it is not very

often tested on field. DC-AC.

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Types of Electrical Failure

OPEN CIRCUIT

CONTAMINATION

PHASE TOPHASE

EARTH

TYPE OFFAILURE

ROTORROTORSTATORSTATOR

NOYESYESNO

YESNOYESYES

YESNONOYES

YESYESYESNO

SURGETESTER

INSULATIONMEASURAMENTOHMIC

RESISTANCE


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Types of Electrical Failure

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INGETEAM S.A.

Avda. Ciudad de la Innovacin, 13E-31621 Sarriguren NavarraTel.: +34 948 28 80 00Fax.: +34 948 28 80 01Web: www.ingeteam.comNIF: A-31-270853

THANK YOU FOR YOUR ATTENTIONTHANK YOU FOR YOUR ATTENTION

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