Handbook of Large Turbo-Generator Operation and Maintenance

The comprehensive guide for large turbo-generator operation and maintenance

The Handbook of Large Turbo-Generator Operation and Maintenance is an expanded 3rd edition of the authors' second edition of the same book. This updated revision covers additional topics on generators and provides more depth on existing topics. It is the ultimate resource for operators and inspectors of large utility and industrial generating facilities who deal with multiple units of disparate size, origin, and vintage. The book is also an excellent learning tool for students, consulting and design engineers. It offers the complete scope of information regarding operation and maintenance of all types of turbine-driven generators found in the world.

Based on the authors' ver eighty combined years of generating station and design work experience, the information presented in the book is designed to inform the reader about actual machine operational problems and failure modes that occur in generating stations and other types of facilities. Readers will find very detailed coverage of:

• Design and construction of generators and auxiliary systems
• Generator operation and control, including interaction with the grid
• Monitoring, diagnostics, and protection of turbo-generators
• Inspection practices for the stator, rotor, and auxiliary systems
• Maintenance testing, including electrical and non-destructive examination
• Ideas on maintenance strategies and life cycle management
• Additional topics on uprating of generators and long term storage are also included

The Handbook of Large Turbo-Generator Operation and Maintenance comes packed with photos and graphs, commonly used inspection forms, and extensive references for each topic. It is an indispensable reference for anyone involved in the design, construction, operation, protection, maintenance, and troubleshooting of large generators in generating stations and industrial power facilities.

Autorentext

GEOFF KLEMPNER, BASc, is a large generator specialist, located in Toronto, Canada. He is an IEEE Fellow and has served on numerous IEEE committees and standards working groups for large generators and is also a contributor to CIGRE on large rotating electrical machines. ISIDOR KERSZENBAUM, PHD, is an IEEE Fellow, located in Irvine, CA. He is a generator specialist consulting to power plants on operation, maintenance and trouble-shooting of large motors and generators.

Klappentext
THE COMPREHENSIVE GUIDE FOR LARGE TURBO-GENERATOR OPERATION AND MAINTENANCE The Handbook of Large Turbo-Generator Operation and Maintenance is an expanded 3rd edition covering additional topics on generators and provides more depth on existing topics. It is the ultimate resource for operators and inspectors of large utility and industrial generating facilities who deal with multiple units of disparate size, origin, and vintage. The book is also an excellent learning tool for students, consulting and design engineers. It offers the complete scope of information regarding operation and maintenance of all types of turbine-driven generators found in the world. Based on the authors' over eighty combined years of generating station and design work experience, the information presented in the book is designed to inform the reader about actual machine operational problems and failure modes that occur in generating stations and other types of facilities. Readers will find very detailed coverage of:

• Design and construction of generators and auxiliary systems
• Generator operation and control, including interaction with the grid
• Monitoring, diagnostics, and protection of turbo-generators
• Inspection practices for the stator, rotor, and auxiliary systems
• Maintenance testing, including electrical and nondestructive examination
• Ideas on maintenance strategies and life cycle management
• Additional topics on uprating of generators and long term storage are also included The Handbook of Large Turbo-Generator Operation and Maintenance comes packed with photos and graphs, commonly used inspection forms, and extensive references for each topic. It is an indispensable reference for anyone involved in the design, construction, operation, protection, maintenance, and troubleshooting of large generators in generating stations and industrial power facilities.

Inhalt
Preface xxi

Acknowledgments xxvii

I THEORY, CONSTRUCTION, AND OPERATION

1 PRINCIPLES OF OPERATION OF SYNCHRONOUS MACHINES 3

1.1 Introduction To Basic Notions On Electric Power 4

1.1.1 Magnetism and Electromagnetism 4

1.1.2 Electricity 7

1.2 ElectricalMechanical Equivalence 8

1.3 Alternating Current (ac) 8

1.4 Three-Phase Circuits 20

1.5 Basic Principles of Machine Operation 22

1.5.1 Faraday's Law of Electromagnetic Induction 22

1.5.2 AmpereBiotSavart's Law of Electromagnetic-Induced Forces 22

1.5.3 Lenz's Law of Action and Reaction 23

1.5.4 Electromechanical Energy Conversion 24

1.6 The Synchronous Machine 26

1.6.1 Background 26

1.6.2 Principles of Construction 28

1.6.3 Rotor Windings 32

1.6.4 Stator Windings 34

1.7 Basic Operation of The Synchronous Machine 37

1.7.1 No-Load Operation 44

1.7.2 Motor Operation 46

1.7.3 Generator Operation 47

1.7.4 Equivalent Circuit 47

1.7.5 Machine Losses 50

Additional Reading 50

2 GENERATOR DESIGN AND CONSTRUCTION 53

2.1 Stator Core 55

2.1.1 General Construction Features 55

2.1.2 Insulated versus Noninsulated Cores 60

2.1.3 Cores Built with Consolidated Donuts 62

2.1.4 Robotic versus Hand Core Stacking 62

2.1.5 Core Stacking Pressure and Tightness 63

2.2 Stator Frame 64

2.2.1 General Construction Features 64

2.2.2 Caged Core Design 66

2.2.3 Grounding of Stator Frames 66

2.3 Flux and Armature Reaction 67

2.4 Electromagnetics 70

2.5 End-Region Effects and Flux Shielding 74

2.5.1 Stator Core-End Copper Flux Shields/Screens 75

2.5.2 Stator Core-End Flux Shunts 77

2.5.3 Combination Stator Core-End Flux Screens and Flux Shunts 78

2.5.4 Stator Core-End Packet Stepping 78

2.5.5 Stator Core-End Tooth Slitting 81

2.5.6 Keybar Shorting Straps 83

2.6 Stator Core and Frame Forces 84

2.7 Stator Windings 85

2.7.1 Stator Winding Configuration and Installation Overview 85

2.7.2 Overview of Stator Winding Design Considerations 89

2.7.3 Fundamental Concepts 93

2.7.4 Winding Structure 94

2.7.5 Winding Specific Layouts 95

2.7.6 Basic Formulae 96

2.7.7 Conductor Bar Construction 98

2.8 Stator Winding Wedges 111

2.9 End-Winding Support Systems 114

2.10 Stator Terminal Connections 117

2.11 Rotor Forging 118

2.12 Rotor Winding 124

2.13 Rotor Winding Slot Wedges 131

2.14 Amortisseur (Damper) Winding 133

2.15 Retaining Rings 133

2.16 Bore Copper and Terminal Connectors 143

2.17 Slip/collector Rings and Brush Gear 147

2.18 Rotor Couplings 149

2.19 Rotor Turning Gear 151

2.20 Bearings 152

2.21 Air and Hydrogen Cooling 152

2.21.1 Basic Cooling Arrangements 155

2.22 Rotor Fans 156

2.23 Hydrogen Containment 158

2.23.1 Journal-Type Hydrogen Seals 161

2.23.2 Thrust Collar-Type Hydrogen Seals 161

2.24 Hydrogen Coolers 162

2.25 Air Coolers 164

2.26 Water-Cooled Rotors 165

References 166

3 GENERATOR AUXILIARY SYSTEMS 169

3.1 Lube-Oil System 170

3.2 Hydrogen Cooling System 170

3.3 Seal-Oil System 173

3.4 Stator Cooling Water System 176

3.4.1 System Components 177

3.4.2 Stator Cooling Water Chemistry 180

3.4.3 Stator Cooling Water System Conditions 185

3.5 Exciter Systems 187

3.5.1 Types of Excitation Systems 187

3.5.2 Excitation System Performance Characteristics 192

3.5.3 Field Discharge Resistor 193 3.5.4 Automatic Voltag...