Motors | Automation | Energy | Transmission & Distribution | Coatings

Turbogenerators

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Turbogenerators2

Designed for applications in Small Thermoelectric Plants (STP), WEG turbogenerators come in a wide range of powers, defined based on an extensive market research and WEGs experience in supplying and designing turbogenerators, and are suitable for installations with steam and gas turbines, among others.

Turbogenerators

Technical characteristicsg Powers up to 150,000 kVA - 13,800 V - 60 Hz - 3600 rpmg Powers up to 120,000 kVA - 11,000 V - 50 Hz - 3600 rpmg Degree of Protection: IP23 to IP56W/IP65Wg Mounting: IM1001 or IM1005 (B3), IM7311 (D5), IM7315 (D6)g Other characteristics under request

ProjectsWEG products are designed with modern software applications, developed in conjunction with universities from Europe, USA and Brazil, ensuring optimized projects and maximum efficiency of its products.

CertificationsWEGs quality system complies with standards ISO 9001 and ISO 14001. The quality system is audited and certified by the Bureau Veritas Quality Institute. In order to meet the requirements of the worlds most demanding markets, WEG has important certifications from the main important certifying bodies of the world, such as CSA, BVQI, NBR, ABS and DNV.

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Manufacturing Process

Insulation systemWEG MICATHERM insulation system is based on the Vacuum Pressure Impregnation process (VPI), which was developed together with the worlds most renowned suppliers of insulating materials.Using special epoxy resins, this system ensures perfect insulation of the turbogenerator winding, in a process totally free from gases harmful to the environment.For many years the VPI process has shown its efficiency and reliability in rotating electrical machines in many different applications. The insulation system is used in low and high voltage machines that use form wound coils from 380 to 15,000 V.

Winding The winding process adopted by WEG is especially developed and specified for the voltage and application the turbogenerator is intended for. The turbogenerator coils are made with rectangular, form wound copper wire completely insulated with porous mica tape. In the winding process, conductor and semiconductor tapes are also used, enveloping the coils and ensuring the suitable characteristics for the required insulating level.

BalancingAll the rotors are dynamically balanced at the turbogenerator operation speeds, in two symmetry planes. The process is computer-controlled, and it may have three degrees of balancing: regular, reduced or special.Increased useful life of the bearings, as well as of the turbogenerators, and reduction of the vibration level are some of the benefits of a good balancing.

Plasma cutting Laser cutting Vertical lathe

2-pole rotor Winding Impregnation system

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Construction Features

Frame Its main function is to support and protect the turbogenerator, also housing the lamination core and the stator windings.The frame is built in welded steel profiles and sheets, forming a solid and robust set, which is the structural base of the machine, meeting the degree of protection according to the needs of the environment. All the assembly of the frame receives a normalizing heat treatment to relieve the stress caused by the welds.This kind of construction provides excellent structural strength so as to withstand mechanical stresses arising from potential short-circuits and low vibrations, enabling the turbogenerator to meet the severest requirements.

StatorIt is the active magnetic static part of the turbogenerator. It is formed by a core of silicon steel laminations with slots to fit the coils that form the stator winding. The stator core is mounted directly in the frame.

RotorThe rotor consists of active rotating parts, composed of a steel pressed sheet stack, the field winding and damper winding. The rotors of WEG turbogenerators are cylindrical (non-salient poles), and feature slots where the field winding and damper winding are fitted.The shafts are made of forged or rolled steel and machined according to the specifications. The shaft end is normally cylindrical or flanged.

BearingsDepending on the application, the turbogenerators can be supplied with rolling bearings or sleeve bearings.

Sleeve bearingsThe sleeve bearings can have natural lubrication (self-lubrication) or forced lubrication (external lubrication).

Rolling bearingThese bearings are normally composed of ball roller bearings or cylindrical roller bearings, depending on the speed and axial and radial loads which they are subject to, seeing that in some applications special rolling bearings can be used. The rolling bearings can be lubricated with oil or grease.

Brushless exciterThe turbogenerators with the brushless excitation system have a main rotating exciter, normally located in a compartment in the rear of the turbogenerator.The main exciter stator is supplied with DC current by the voltage regulator, and the rotor of the main exciter supplies the field winding of the turbogenerator through a rotating three-phase rectifier bridge.

Brushless excitation with auxiliary exciter (PMG)The auxiliary exciter or PMG (Permanent Magnet Generator) is a small generator built in WEG brushless turbogenerators intended to supply the power circuit of the voltage regulator.The PMG rotor, installed on the shaft of the turbogenerator, is composed of a sheet stack where the permanent magnets are mounted.The PMG stator is normally mounted on the frame of the external compartment where the main exciter stator is also installed.

Brushless excitation without auxiliary exciter This type of excitation is optional for WEG turbogenerators.The turbogenerator does not have auxiliary exciter (PMG) and the power circuit of the voltage regulator is supplied by means of the excitation transformer connected to the main terminals of the turbogenerator. The excitation transformer can be installed in the terminal box of the turbogenerator (under request) or in customers excitation panel.

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Cooling

Accessories

The most used types of cooling are:

g Open, self-ventilated turbogenerators, degree of protection IP23g Closed turbogenerators with air-water heat exchanger, degree of protection IP54 to IP65W

Standard:g Pt-100 type temperature sensor on the stator phasesg Pt-100 type temperature sensor on the bearingsg Space heaterg Thermometer (01 per bearing) without electrical contactsg Anchor plateg Grounding brush on the shaftg Sight glass of oil flowg Flow switch for the oil inlets of the turbogenerators

bearings (01 per inlet) with electrical contactg Sight glass of water flowg Flow switch without electrical contacts in the cooling water

inlet and outlet

Open, self-ventilated turbogeneratorMounting IM1001 (B3)

Open, self-ventilated turbogeneratorMounting IM7315 (D6)

Closed turbogenerator with air-water heat exchangerMounting IM7315 (D6)

Closed turbogenerator with air-water heat exchangerMounting IM1005 (B3)

g Water leak detectorg Thermometer without electrical contacts in the water

inlet and outletg Thermometer without electrical contacts for the air:

(02 inlet + 01 outlet)g Leveling platesg Anchors

Optional:g Voltage regulatorg High-pressure oil injection system (Hydrostatic Jacking)g Potential transformer (PT)g Current transformer (CT)

In addition to the cooling systems mentioned, the turbogenerators can be supplied with forced ventilation, sealed with air-air heat exchanger, inlet and outlet of air by ducts, and other means of cooling, to better meet the characteristics of the application and environment where they are installed.

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Tests

Technical Assistance and Services

Parts and Components

WEG turbogenerators are tested according to NBR, IEC and IEEE standards in modern laboratories capable of testing medium and high-voltage generators with power up to 20,000 kVA and voltages up to 15,000 V, with fully computerized monitoring and highly accurate controls. The tests are divided into three categories: routine, type and special tests.

Routine testsg Cold resistanceg Phase sequenceg Measurement of balance between

phasesg Saturation with no loadg Permanent three-phase short circuitg High voltageg Insulation resistance

Special testsg V curveg Vibrationg Noise levelg Overspeedg Stress on the shaft

Type testsg Cold resistanceg Phase sequenceg Measurement of balance between

phasesg Recording of wave formg Harmonics distortiong Saturation with no loadg Permanent three-phase short circuitg Losses and efficiencyg Negative sequence reactance (X2)g Zero sequence reactance (X0)

g Instantaneous three-phase short circuitg Temperature rise (short method - circuit + no load)g High voltageg Insulation resistanceg Polarization index

Technical assistanceWEG provides its customers with technical assistance services responsible for all after sale support. These services include a 24/7 customer support, on site services such as machines diagnosis, repair, start-up and commissioning and also assembly supervision. Our highly trained and experienced team is capable of handling complex issues in the field and provide remote support with state-of-the-art equipment, which produces reliable results. We also offer our worldwide repair shop network.After years in operation, turbogenerators need restoration to continue working properly. For this restoration, it is advisable to use original parts supplied by the manufacturer.WEGs team is available for immediate support and assistance with the proper identification of components.

After years in operation, turbogenerators need restoration to continue working properly. For this restoration, it is advisable to use original parts supplied by the manufacturer.WEGs team is available for immediate support and assistance with the proper identification of components.

Services WEG, market leader in motors and generators, also offers services of checkup, restoration and repowering on medium and large electrical machines performed in the factory or in the field, including other brands, as follows:

g DC generators and motorsg Three-phase induction motors (cage or rings of low, medium and high voltage)g Synchronous motors (with or without brushes, low, medium and high voltage)g Turbogeneratorsg Hydrogenerators

When performing repair services, WEG uses the same technology and processes used in the manufacture of new machines.

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Turbogenerators 7

Customer: USINA DEL CHIRACountry: Peru5000 kVA, 13,800 V, 4 poles, frame 63010,000 kVA, 11,900 V, 4 poles, frame 800Application: Steam turbine

Customer: USINA INTERLAGOS Country: Brazil50,000 kVA, 13,800 V, 4 poles, frame 1250Application: Steam turbine

Customer: USINA VIRALCOOL Country: Brazil18,750 kVA, 13,800 V, 4 poles, frame 1000Application: Steam turbine

Customer: CIASACountry: Bolivia12,500 kVA, 6300 V, 4 poles, frame 900Application: Steam turbine

Applications

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