SYnchronous Machine Design Complete

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Subject: AC Machine Design

Chapter: Synchronous
Machine design
3170909

Dr. Amit Ved


 Introduction to synchronous machine
 Constructional details of synchronous machine
 Classification of synchronous machine
OUTLINE  Comparison between Salient pole and Non-
Salient Pole synchronous machine
 Output Equation
 The most commonly used machine for generation of
electrical power for commercial purpose is the
synchronous generator.
Introduction to
 Such a synchronous generator is also referred to as
synchronous alternator since it generates alternating voltage.
machine  Synchronous machines are AC machines that have a
field circuit supplied by an external DC source.
 Synchronous machines are having two major parts
namely stationary part stator and a rotating field system
called rotor.
 In a synchronous generator, a DC current is applied to
Introduction to the rotor winding producing a rotor magnetic field. The
rotor is then driven by external means producing a
synchronous rotating magnetic field, which induces a 3-phase voltage
machine within the stator winding.
 Field windings are the windings producing the main
magnetic field (rotor windings for synchronous
machines); armature windings are the windings where
the main voltage is induced (stator windings for
synchronous machines).
 Synchronous generator according to their construction,
are divided into the following two classifications:
Construction of 1. Rotating armature type: It has stationary field poles and
Synchronous rotating armature.
Machine 2. Rotating field type: It has stationary armature or stator
and rotating field poles.
 Most synchronous generator or alternators have rotating
field and stationary armature.
 A stationary armature is more easily insulted for the high voltage for
which the alternator is designed.
 The bracing of armature windings can be made better mechanically
against high electromagnetic forces due to large short-circuit currents
when the armature windings are in the stator.
Advantages of  The armature windings, being stationary, are not subjected to vibration
and centrifugal forces.
the rotating  The output current can be taken directly from fixed terminals on the
field type stationary armature without using slip rings, brushes.
alternators  The rotating field is supplied with direct current. Only two slip rings are
required to provide direct current for the rotating field, while at least
three slip rings would be required for a rotating armature.
 Rotating field is comparatively light and can be constructed for high
speed rotation.
 The stationary armature may be cooled more easily because the armature
can be made large to provide a number of cooling ducts.
 The basic construction of a synchronous generator and a
synchronous motor is the same.
 Similar to other rotating machines, an alternator consists
of two main parts namely, the stator and the rotor.
Construction of 1. The stator is the stationary part of the machine. It
Synchronous carries the armature winding in which the voltage
is generated. The output of the machine is taken
Machine from the stator.
2. The rotor is the rotating part of the machine. The
rotor produces the main field flux.
 The stator consists of an armature made of laminations
of silicon steel having slots on its inner periphery to
accommodate armature windings.
 Fig. shows a cross sectional view of the stator of a three
phase two pole synchronous machine.
Construction of
Stator
 Construction of Rotor
Two types of rotors are used in alternators. (i) Salient pole type
(ii) Smooth cylindrical type
(i) Salient (or projecting ) Pole Type
 The term salient means projecting. A salient pole rotor
Construction of consists of poles projecting out from the surface of the rotor
Rotor core. Salient pole rotors are normally used for rotors with
four or more poles.
(ii) Smooth Cylindrical Type
 A cylindrical rotor machine is also called a non-salient pole
rotor machine. It has its rotor so constructed that it forms a
smooth cylinder. This type of rotor is used for alternators
which are coupled to steam turbines which run at very high
speeds. The number of poles of the rotor are two or four.
 The salient pole field structure has the following special
features:
Features of (i) They have large diameter and short axial length.
Salient Field (ii) Poles are laminated to reduce eddy current losses.
Structure (iii) These are employed with hydraulic turbines or diesel
engines. The speed is always less than 1500 rpm.
 The non-salient field structure has the following special
features:
(i) They are of small diameter and of very long axial
length.
(ii) Robust construction.
Features of (iii) High operating speed (3000 rpm)
Non-Salient (iv) Noiseless operation.
Field Structure (v) Dynamic balancing is better.
(vi) No need to provide damper windings, except in
special cases to assist synchronizing.
(vii) Better emf waveform.
Difference
between salient
pole & Non-
Salient pole
alternators
1.Hydro-generators : The generators which are driven by
hydraulic turbines are called hydro-generators. These
are run at lower speeds less than 1000 rpm.
2.Turbogenerators: These are the generators driven by
Types of steam turbines. These generators are run at very high
speed of 1500rpm or above.
synchronous
3.Engine driven Generators: These are driven by IC
machines engines. These are run at a speed less than 1500 rpm.
 Hence the prime movers for the synchronous generators
are Hydraulic turbines, Steam turbines or IC engines.
 Hydraulic Turbines:
 Pelton wheel Turbines: Water head 400 m and above
 Francis turbines: Water heads up to 380 m
 Keplan Turbines: Water heads up to 50 m
Types of  Steam turbines: The synchronous generators run by
Hydraulic steam turbines are called turbogenerators or turbo
alternators.
Turbine  Steam turbines are to be run at very high speed to get
higher efficiency and hence these types of generators are
run at higher speeds.
 Diesel Engines: IC engines are used as prime movers for
very small rated generators.
 Consists of two sets of windings:
➢3 phase armature winding on the stator distributed with centers 120°
apart in space
➢field winding on the rotor supplied by DC
 Two basic rotor structures used:
Physical ➢ Salient or projecting pole structure for hydraulic units (low speed)
➢ Cylindrical/round rotor structure for thermal units (high speed)
Description of a
 Salient poles have concentrated field windings; usually also carry damper
Synchronous windings on the pole face.
Machine  Cylindrical/Round rotors have solid steel rotors with distributed windings.
 Nearly sinusoidal space distribution of flux wave shape obtained by:
➢ distributing stator windings and field windings in many slots (round
rotor);
➢ shaping pole faces (salient pole)
 These types of machines are constructed based on the
water head available and hence these machines are low
speed machines
 These machines are constructed based on the mechanical
Construction of consideration.

Hydro-  For the given frequency the low speed demands large
number of poles and consequently large diameter.
generators  The machine should be so connected such that it permits
the machine to be transported to the site. It is a normal to
practice to design the rotor to withstand the centrifugal
force and stress produced at twice the normal operating
speed.
Stator Core
The stator is the outer stationary part of the machine,
which consists of
 The outer cylindrical frame called yoke, which is made
either of welded sheet steel, cast iron.

Stator Core  The magnetic path, which comprises a set of slotted


steel laminations called stator core pressed into the
cylindrical space inside the outer frame.
 The magnetic path is laminated to reduce eddy currents,
reducing losses and heating. CRGO laminations of 0.5
mm thickness are used to reduce the iron losses.
 A set of insulated electrical windings are placed inside
the slots of the laminated stator.
 The cross-sectional area of these windings must be large
enough for the power rating of the machine.
 For a 3-phase generator, 3 sets of windings are required,
one for each phase connected in star.
Stator Core  In case of generators where the diameter is too large
stator lamination can not be punched in on circular
piece.
 A number of segments are assembled together to form
one circular laminations.
 All the laminations are insulated from each other by a
thin layer of varnish.
Cut section
view of Stator
Core
Stator and rotor
of Salient Pole
Alternator
Real view of
Salient pole
stator and rotor
 For a given slot mmf, reluctance offered by (i) open
slots is more (ii) semi-closed slots is less and (iii) closed
slots is still less. Consequently the open slots have less
leakage reactance than semi-closed slots, whereas the
closed slots have more leakage reactance than semi
closed.
Stator Slots  The wide open type slot has the advantage of permitting
easy installation of form wound coils and their easy
removal in case of repair. But it has the disadvantage of
distributing the air gap flux into bunches or tufts, that
produces ripples in the wave of the generated emf.
 The semi closed type slots are better in this respect, but
do not make the use of form wound coils.
The closed slots do not disturb the air gap flux but
 they tend increase the inductance of the windings

Stator slots  The armature conductors have to be threaded through,


thereby increasing initial labour and cost of winding and
 They present a complicated problem of end connection.
Hence they are rarely used.
 The stator winding of all synchronous generator is star
connected with neutral earthed.
 This arrangement has the advantage that the winding has
Stator Winding to be insulated to earth for the phase voltage and not the
line voltage.
 Star connection also has the advantage that it eliminates
all triple frequency harmonics from the line voltage.
 Rotor of water wheel generator consists of salient poles.
 Poles are built with thin silicon steel laminations of
0.5mm to 0.8 mm thickness to reduce eddy current
laminations.
 The laminations are clamped by heavy end plates and
Rotor secured by studs or rivets.

Construction  For low speed rotors poles have the bolted on


construction for the machines with little higher
peripheral speed poles have dove tailed construction as
shown in Figs.
 Generally rectangular or round pole constructions are
used for such type of alternators. However the round
poles have the advantages over rectangular poles.
 Generators driven by water wheel turbines are of either
horizontal or vertical shaft type.
 Generators with fairly higher speeds are built with
horizontal shaft and the generators with higher power
ratings and low speeds are built with vertical shaft
Rotor design.
Construction  Vertical shaft generators are of two types of designs:
(i) Umbrella type where in the bearing is mounted below
the rotor
(ii) Suspended type where in the bearing is mounted
above the rotor.
 In case of turbo alternator the rotors are manufactured
form solid steel forging.
 The rotor is slotted to accommodate the field winding.
 Normally two third of the rotor periphery is slotted to
accommodate the winding and the remaining one third
unslotted portion acts as the pole.
Rotor
 Rectangular slots with tapering teeth are milled in the
Construction rotor.
 Generally rectangular aluminum or copper strips are
employed for filed windings.
 The field windings and the overhangs of the field
windings are secured in place by steel retaining rings to
protect against high centrifugal forces.
 Hard composition insulation materials are used in the
slots which can withstand high forces, stresses and
temperatures.
 Perfect balancing of the rotor is done for such type of
Rotor rotors.
Construction  Damper windings are provided in the pole faces of
salient pole alternators.
 Damper windings are nothing but the copper or
aluminum bars housed in the slots of the pole faces.
 Turbo alternators are normally designed with two poles
with a speed of 3000 rpm for a 50 Hz frequency.
Relative  Hence peripheral speed is very high. As the diameter is
dimensions of proportional to the peripheral speed, the diameter of the
Turbo and high speed machines has to be kept low.

water wheel  For a given volume of the machine when the diameter is
kept low the axial length of the machine increases.
alternators  A turbo alternator will have small diameter and large
axial length.
 However in case of water wheel generators the speed
will be low and hence number of poles required will be
Relative large.
dimensions of  This will indirectly increase the diameter of the
Turbo and machine.

water wheel  Hence for a given volume of the machine the length of
the machine reduces.
alternators  So the water wheel generators will have large diameter
and small axial length in contrast to turbo alternators.
 Synchronous machines are designed to obtain
the following information.
Introduction to I. Main dimensions of the stator frame.
Design II. Complete details of the stator windings.
III. Design details of the rotor and rotor
winding.
IV. Performance details of the machine.
 To proceed with the design and arrive at the design
information the design engineer needs the following
information.
1) Specifications of the synchronous machine.
Introduction to 2) Information regarding the choice of design
Design parameters.
3) Knowledge on the availability of the materials.
4) Limiting values of performance parameters.
5) Details of Design equations.
 Important specifications required to initiate the design
procedure are as follows:
▪ Rated output of the machine in kVA or MVA
▪ Rated voltage of the machine in kV
Specifications ▪ Speed
▪ Frequency
of the ▪ type of the machine generator or motor
synchronous ▪ type of rotor salient pole or non salient pole
machine ▪ connection of stator winding in star or delta
connected
▪ limit of temperature
▪ details of prime mover etc.
 Internal diameter and gross length of the stator forms the
main dimensions of the machine.
Main  In order to obtain the main dimensions it is required to
Dimensions develop the relation between the output and the main
dimensions of the machine.
 This relation is known as the output equation.
Subject: AC Machine Design
Chapter: Induction motor
design
3170909

Dr. Amit Ved


It is hereby declared that the production of the said
content is meant for non-commercial, scholastic and
research purposes only.
We admit that some of the content or the images
provided in this channel's videos may be obtained
through the routine Google image searches and few of
Disclaimer them may be under copyright protection. Such usage is
completely inadvertent.

It is quite possible that we overlooked to give full


scholarly credit to the Copyright Owners. We believe
that the non-commercial, only-for-educational use of
the material may allow the video in question fall under
fair use of such content. However we honour the
copyright holder's rights and the video shall be deleted
from our channel in case of any such claim received by
us or reported to us.

28-10-2023
● Construction of synchronous machine
Revision

SLO
● Output equation, selection of Bav, ac, L/τ ratio
● example

DACM
Design of 3phase
Induction Machine
Output of the machine Q = 3Vph Iph x 10-3 kVA
Assuming Induced emf Eph = Vph
Output of the machine Q = 3Eph Iph x 10-3 kVA
Output Induced emf
𝐸𝑝ℎ = 4.44 × 𝑓𝜑𝑇𝑝ℎ 𝐾𝑤 = 2.22𝑓𝜑𝑍𝑝ℎ 𝐾𝑤
Equation
Frequency of generated emf
𝑃𝑁 𝑃𝑛𝑠
𝑓= =
120 2
Air gap flux per pole 𝜑 = 𝐵𝑎𝑣.𝜋𝐷𝐿ൗ𝑝
3.𝐼𝑝ℎ 𝑍𝑝ℎ
Specific electric loading ac =
𝜋𝐷
𝑎𝑐.𝜋.𝐷
Hence 𝑍𝑝ℎ 𝐼𝑝ℎ =
3
𝑂𝑢𝑡𝑝𝑢𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑎𝑐ℎ𝑖𝑛𝑒
Output 𝑄 = 3 × 4.44.
𝑝. 𝑛𝑠 𝐵𝑎𝑣 . 𝜋𝐷𝐿
. . 𝑇𝑝ℎ 𝐾𝑤 . 𝐼𝑝ℎ . 10−3
Equation 2 𝑝
𝑍𝑝ℎ
Now we know that 𝑇𝑝ℎ =
2
𝑂𝑢𝑡𝑝𝑢𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑎𝑐ℎ𝑖𝑛𝑒
𝑝. 𝑛𝑠 𝐵𝑎𝑣 . 𝜋𝐷𝐿 𝑍𝑝ℎ
𝑄 = 3 × 4.44. . . 𝐾𝑤 . . 𝐼𝑝ℎ . 10−3
2 𝑝 2
𝑂𝑢𝑡𝑝𝑢𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑎𝑐ℎ𝑖𝑛𝑒

𝑎𝑐. 𝜋. 𝐷
= 3.33 × 𝑛𝑠 . 𝐵𝑎𝑣 . 𝜋𝐷𝐿𝐾𝑤 . . 10−3
3
Output = 1.11 × 𝑛𝑠 . 𝐵𝑎𝑣 . 𝜋𝐷𝐿𝐾𝑤 . 𝑎𝑐. 𝜋. 𝐷 × 10−3
Equation = 1.11 × 𝜋 2 . 𝐷2 . 𝐿. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 𝑛𝑠 × 10−3
= (11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 10−3 )𝐷2 . 𝐿. 𝑛𝑠
= 𝐶0 . 𝐷2 . 𝐿. 𝑛𝑠

Where 𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 10−3


1. Iron loss: A high value of flux density in the air gap
leads to higher value of flux in the iron parts of the
machine which results in increased iron losses and
reduced efficiency. Therefore a lower value of gap
Choice of density should be used in order to increase efficiency
Specific and to decrease temperature rise.
magnetic 2. Voltage: When the machine is designed for higher
voltage, the space occupied by the insulation becomes
loading more and smaller space is left for the teeth. Therefore
lower value of gap density should be used in high
voltage machines to avoid excessive value of density
in teeth and core.
3. Transient short circuit current: A high value of gap
density results in decrease in leakage reactance and
hence increased value of armature current under short
circuit conditions. Therefore a lower value of gap
density should be used to limit the initial
Choice of electromagnetic forces under short circuit conditions.
Specific 4. Stability: The maximum power output of a machine
magnetic under steady state condition is inversely proportional
to synchronous reactance. If higher value of flux
loading density is used it leads to smaller number of turns per
phase in armature winding. This results in reduced
value of leakage reactance and hence increased value
of power and hence increased steady state stability.
5. Parallel operation: The satisfactory parallel operation of
Choice of synchronous generators depends on the synchronizing
power. Higher the synchronizing power higher will be the
Specific ability of the machine to operate in synchronism. The
magnetic synchronizing power is inversely proportional to the
synchronous reactance and hence the machines designed
loading with higher value air gap flux density will have better
ability to operate in parallel with other machines.
 For salient pole machines, The value of 𝐵𝑎𝑣 is
Value of considered from 0.52𝑤𝑏Τ𝑚2 to 0.65 𝑤𝑏Τ𝑚2 .
Specific  For non-salient pole/cylindrical machines, The
Magnetic value of 𝐵𝑎𝑣 is considered from 0.54𝑤𝑏Τ𝑚2 to
loading 0.65 𝑤𝑏Τ𝑚2 .
1. Copper loss: Higher the value of q larger will be the
number of armature of conductors which results in
higher copper loss. This will result in higher
temperature rise and reduction in efficiency.
Choice of
2. Voltage: A higher value of q can be used for low
Specific voltage machines since the space required for the
Electric insulation will be smaller.
loading 3. Stray load losses: With increase of q stray load losses
will increase. Values of specific magnetic and specific
electric loading can be selected from Design Data
Hand Book for salient and non-salient pole machines.
4. Synchronous reactance: High value of q leads to
Choice of higher value of leakage reactance and armature
Specific reaction and hence higher value of synchronous
reactance. Such machines will have poor voltage
Electric regulation, lower value of current under short circuit
loading condition and low value of steady state stability limit
and small value of synchronizing power.
 For salient pole machines, The value of 𝑎𝑐 is
Value of considered from 20000 𝐴Τ𝑚 to 40000 𝐴Τ𝑚.
Specific  For non-salient pole/cylindrical machines, The
Electric value of 𝑎𝑐 is considered from 50000 𝐴Τ𝑚 to
loading 75000 𝐴Τ𝑚.
 Inner diameter and gross length of the stator can be
calculated from 𝐷2 𝐿 product obtained from the output
equation. To separate suitable relations are assumed
between D and L depending upon the type of the
generator.
Design of  In case of salient pole machines either round or
rectangular pole construction is employed. In these types
Salient Pole of machines the diameter of the machine will be quite
Machines larger than the axial length.
 The selection of Diameter depends upon:
1. Type of poles used
2. The permissible peripheral speed
 Round Poles: The ratio of pole arc to pole pitch may be
assumed varying between 0.6 to 0.7 and pole arc may be
taken as approximately equal to axial length of the stator
core. Hence
Design of Axial length of the core/ pole pitch = 𝐿Τ𝜏 = 0.6 to 0.7
Salient Pole  Rectangular poles: The ratio of pole arc to pole pitch
Machines may be assumed varying between 1 to 5 and a suitable
value may be assumed based on the design
specifications not more than 3.
Axial length of the core/ pole pitch = 𝐿Τ𝜏 = 1 to 3
(Optimum Design)
1. Find the main dimension of a 100 MVA , 11 KV , 50
Hz, 150 r.p.m. , 3 phase water wheel generator. The
𝑤𝑏
average gap density is 0.65 2 and ampere conductor
𝑚
Numerical per metre is 40000. The peripheral speed should not
exceed 65 𝑚Τ𝑠𝑒𝑐 at normal running speed in order to
problem on limit the run-away peripheral speed.
basis of 150
Solution: 𝑛𝑠 = = 2.5 𝑟𝑝𝑠
Calculation 60
2.𝑓 2×50
main Number of poles 𝑝 = = = 40
𝑛𝑠 2.5

dimensions Assuming 𝐾𝑤 = 0.955


Output Co-efficient 𝐶0 = 11 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 10−3
𝐶0 = 11 × 0.65 × 40000 × 0.955 × 10−3 = 273.13
2 𝑄 100×103
 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝐷 𝐿 = = = 146.45 𝑚3 (1)
𝐶0 ×𝑛𝑠 273.13×2.5
𝐿
 Taking Circular pole design , Assuming ratio as 0.6 to
Numerical 𝜏
0.7.
problem on 𝐿 𝐿
 Considering it as 0.65, = 0.65, 𝜋.𝐷 = 0.65
basis of 𝜏 ൗ𝑃
𝜋.𝐷
Calculation  As P = 40 , 𝐿 =
40
× 0.65 = 0.051D
main  Now from Equation (1), 0.051𝐷3 = 146.45
dimensions  D = 14.21 m
 Peripheral speed 𝑣𝑎 = 𝜋. 𝐷. 𝑛𝑠 = 𝜋 × 14.21 × 2.5 =
111.60 𝑚Τ𝑠𝑒𝑐
 As we are getting peripheral speed more than
𝐿
permissible limit of 60 m/sec. So we have to change
𝜏
ratio.
Numerical  As we have to decrease the peripheral speed, So from
problem on the peripheral speed equation, 𝑣𝑎 = 𝜋. 𝐷. 𝑛𝑠 𝜋 & 𝑛𝑠 is,
constant.
basis of  Now to decrease 𝑣𝑎 , we have to minimize D and 𝐷3 .
Calculation  So circular pole design is not suitable here as it has less
𝐿
main value of ratio. So we consider the rectangular poles
𝜏
𝐿
dimensions with ratio as 1 to 5.
𝜏
𝐿
 Now again assuming ratio between 1 to 5 and getting
𝜏
the value of 𝑣𝑎 within the limit.
𝑳 𝑳 = 𝑿. 𝑫 𝑫𝟑 (𝒎𝟑 ) 𝑫 (𝐦) 𝒗𝒂 = 𝝅. 𝑫. 𝒏𝒔 𝑳 (m)
𝝉 (m/sec)

1 L = 0.07853 D 1864.65 12.30 96.669


Numerical
problem on 2 L = 0.15706 D 926.14 9.7474 76.55
basis of
3 L = 0.23559 D 617.404 8.515 66.8774
Calculation
main 4
dimensions
5 L = 0.39265 D 370.45 7.1819 56.4070 2.8199
1. Find 𝑛𝑠 and number of poles.
2. Find output coefficient using 𝐶0 =
11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 10−3 ( 𝐾𝑤 = 0.955)
𝑄 (𝐾𝑉𝐴)
Procedure to 3. Find Product 𝐷2 𝐿 = .
𝐶0 ×𝑛𝑠
solve 4. Assume ratio of 𝐿Τ𝜏 and find a relation between D &
L.
5. From product 𝐷2 𝐿 , find D & L separately.
6. Also check the limit of peripheral speed 𝑣𝑎 = 𝜋. 𝐷. 𝑛𝑠
2. Determine the main dimension for a 1000KVA, 50 Hz, 3 phase ,
𝑤𝑏
375 r.p.m. alternator. The average gap density is 0.55 2 and
𝑚
ampere conductor per metre is 28000. Use rectangular pole and
assume suitable value of 𝐿Τ𝜏 to limit maximum permissible
peripheral speed up to 50 𝑚Τ𝑠𝑒𝑐. The run away speed is 1.8
times of synchronous speed.
Subject: ACMD
Chapter: Synchronous machine
design-2

Dr. Amit Ved


It is hereby declared that the production of the said
content is meant for non-commercial, scholastic and
research purposes only.
We admit that some of the content or the images
provided in this channel's videos may be obtained
through the routine Google image searches and few of
Disclaimer them may be under copyright protection. Such usage is
completely inadvertent.

It is quite possible that we overlooked to give full


scholarly credit to the Copyright Owners. We believe
that the non-commercial, only-for-educational use of
the material may allow the video in question fall under
fair use of such content. However we honour the
copyright holder's rights and the video shall be deleted
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28-10-2023
 Construction of Synchronous machine with parts
 Output equation Q= 𝐶0 . 𝐷2 . 𝐿. 𝑛𝑠 ,𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 10−3
Revision  Selection of Bav 0.52 𝑤𝑏 Τ𝑚2 to 0.65 𝑤𝑏 Τ𝑚2 SPM 0.54 𝑤𝑏 Τ𝑚2 to 0.65
𝑤𝑏 Τ𝑚2 .CM
 Selection of ac 20000 𝐴Τ𝑚 to 40000 𝐴Τ𝑚. SPM, 50000 𝐴Τ𝑚 to 75000 𝐴Τ𝑚 CM
 Round pole L=bs, L/τ 0.6-0.7
 Rectangular pole L/τ 1-5 , should not exceed 3

● Short circuit ratio (SCR) and it’s effect on machine performance


SLO
● Lg,

● Shape of pole face

DACM
Design of 3phase
Induction Machine
Dr. Amit Ved
 Short circuit ratio (SCR)=
Field current req to produce
Vrated on OC / field current
req to circulate rated current
at sc
 If Xd – pu value for rated v
and I.
SCR Ratio  Xd is affected by saturation
Short ckt ratio condition that exists,
 SCR –univalued for machine
as defined at rated voltage
 Turbo alt-0.5-0.7 raised to
1.0-1.5 for capacitive load
(unloaded line or cable)
 Salient pole hydro- 1.0-.1.5
 1. Voltage regulation: L-SCR- Xd-H, more Ixd drop, VR-poor.
 2. Stability: L-SCR- H- Xd, L- stability limit (Pmax ∞ 1/Xd)
 3. parallel Operation: L-SCR- difficult to operate in parallel, H-Xd, L-
Psynch. Becomes more difficult if interconnected through TL. Zline
+ƩZmachine – incr Z, R- Psynch, more sensitive to Torque and Voltage
Effect of SCR dist. R- Psynch-disconnection /shutdown from operation of Autoreclosing
CB.
on machine
 4 Isc-L-SCR, L- Isc as H- Xd, Isc can be limited and thys synchronous gen
performance need not be designed with H-Xd or L-SCR.
 5. Self Excitation: Mc feeding to LTL should not have H-Xd or L – SCR-
leads to HV on OC produced by self exciation owing to Cap current drawn
by TL
 H-SCR- H stability limit and L- regulation , H-Isc, longer airgap, Atf- H –
costlier to build. Present trend is to design mc with lower SCR. This is due
to recent advancement in fast acting control, excitation and protection
 Lg- influence performance of machine.
 H-Lg- H- reluctance to flux by Ata, R- effect of arm reaction, L- Xs,
H-SCR.
 Mc with H-lg, (L-Xd, H- SCR) has
 L-VR, H- stability limit, H- Psynch- mc less sensitive to load Δ
 Moreover – better cooling at gap surface, L- tooth pulsation loss, L
– noise level and L-u/b magnetic pull
Length of air  But, H –ATf required, H-cost
gap Lg
 Ψ= pole arc/pole pitch (b/τ) -0.67-0.75
 if ψ is too H, (>0.75), interpolar leakage flux becomes excessive-
high B in pole body and improper flux dist in armature.
 if ψ is too L, (<0.67), leave insufficient overhang of pole shoe to
support field coil in radial direction.
 Ψ=0.7 commonly
Shape of pole  In SPM, lg is not const over pole arc but incrs towards tips from
face centre to produce reqd flux dist. Obtain sinusoidal flux by shaping
and proportionating of of pole shoe. For exact dist. Lgx at x from
center is as given in fig 12.24
 We may also use profile as shown in 12.25. for mc without damper
wdg, tip of pole face may be rounded off. For mc with damper wdg,
heavier pole face with dotted line is required.
Revision  SCR and it’s effect, selection of Lg, shape of pole face

 Armature design
 Armature winding
next class  Slot dimension
 Elimination of harmonics
Subject: ACMD
Chapter: Synchronous machine
design-2

Dr. Amit Ved


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28-10-2023
 SCR (If for Voc/If for Isc) and it’s effect- VR, stability, parallel op,
Isc, self excitation
Revision  selection of Lg, shape of pole face(pole face profile)

 Armature design
 Armature winding
next class  Slot dimension
 Elimination of harmonics
 1 layer or double layer.
 H- flux /pole-have L- Tph- double layer bar wdg is used.

Arm design  HV machine, L- flux/pole- H- Tph, multiturn coil is used. – choice


between double layer lap (dropped in open slots) or single layer
Type of wdgn concentric wdg(hair pin cols ,pushed through semi enclosed slots)
slots  Double layer winding in open slots have following advantage over
single layer wdg in semi- enclosed slots
coil span
Double layer winding in open slots have following advantages
Tph - Ease in mfgr of coils and lower cost of wdg
Cond selection - Less coils as spare in case of repair
- Fractional slot wdg, fractional pitch coil
Wdg coil and ins. Single layer winding in Semi-enclosed slots have following advantages
Slot dimension - Higher efficiency and quieter op because fo narrow slot opening
- Space factor for slot is higher , no inter layer separator
Lmt - Refer chapter-7 armature wdg.
stator core - Modern practice – double layer wdg, single layer only in continent
 Factors to be considered for arm. Slots
 Balanced wdg- S – selected such as a balanced wdg is obtained.
Some generator without small u/b – no ill effect.
Arm design
 u/b wdg- R- overheating of rotor surface due to space harmonics,
Type of wdgn excessive triplen harmonics current flowing through N, ill effect on
slots load such as Δ- conn motors IM and circulating current in other
generator in parallel
coil span  Cost: L-S-L- cost, fewer coils to wind, ins, place in slot and conn
Tph  Hot spot temp: L-S-bunching of cond (close cond ), L – space for
circulation of air, R-Internal temperature.
Cond selection
 Xl: L-S, Φl- D, Xl-I, , cond lying near each other.
Wdg coil and ins.  Tooth ripples: in field form and consequent pulsation loss in pole
Slot dimension face D as H S is used. Egenerated will be free from ripple.
Lmt  Biron: H-S, H- space taken by ins., narrow teeth, Biron –high and
beyond accepted level, Teeth might become weak and diff to
stator core support on ducts.
 Ys= πD/S, depends on V, for HV mc with large capacities, desirable
Arm design to use large Ys.
Type of wdgn  Ys<=25mm for LV mc
slots  Ys<=40mm for <=6KV
coil span  Ys<60mm for <=15kv
Tph  For large hydro gen, 50-90mm
Cond selection  In SPM, S/p/m =q= 2-4
Wdg coil and ins.  A fractional slot wdg, R- dist factor for high harmonics, R-
Slot dimension generated emf for harmonics, voltage wavefrom free from
harmonics.
Lmt
 Fractional slot wdg is used invariably in sm
stator core
 Highest ampl harmonics in flux dist curve of spm are 5th and 7th,
coil span chosen to R these harmonics. Max R of these harmonics
is given by coil span of 8.33% of pole pitch, provided S/p permits,
Arm design otherwise coil span should be as near to this value as possible.
Type of wdgn
slots
coil span
Tph
Cond selection
Wdg coil and ins.
Slot dimension
Lmt
stator core
Arm design
Type of wdgn
slots
coil span
Tph
Cond selection
Wdg coil and ins.
Slot dimension
Lmt
stator core
 Single turn bar classB(Ia>1500A), 2 cond in slot
 Multi turn :
 HV machine, L- flux/pole- H- Tph, multiturn coil is used. – choice
Arm design between double layer lap (dropped in open slots) or single layer
concentric wdg(hair pin cols ,pushed through semi enclosed slots)
Type of wdgn
 Synthetic resin and mica paper ins.
slots
coil span
Tph
Cond selection
Wdg coil and ins.
Slot dimension
Lmt
stator core
Arm design
Type of wdgn
 Bt at no load <=1.7-1.8 wb/m2
slots
 Wt(min)= Φ/(ψ(S/p)Li1.8)
coil span
 Parallel sided slot is used.,teeth will be tapered. Min width at airgap
Tph
 Ws(max)=Ys- Wt(min), ds not to exceed 3Ws.
Cond selection
 Deeper slot for high Xl and limit Isc
Wdg coil and ins.
Slot dimension
Lmt
stator core
Arm design
Type of wdgn
slots
coil span
Tph
Cond selection
Wdg coil and ins.
Slot dimension
Lmt
stator core
 Primary src of harmonics- non sinusoidal field form, if made
sinusoidal – harmonics are eliminated. A field form can be made
nearly sinusoidal by following process.
 Major reluctance to path of Φ is airgap. If airgap varies
sinusoidally, Φ will vary sinusoidally. (Const MMF). In SPM,
airgap length under pole shoe –sinusoidal, min at pole centre and
gradually increasing at pole tips. Approx. of sinusoidal field form
by skewing the pole face.
Elimination of  In cylindrical rotor, lg is const, only way it may provide sinusoidal
field form is to make ATf sinusoidal, done by distributing wdg in
harmonics diff slots.
 Saturation of iron pars, field form can not be sinusoidal in SPM ,
evenif airgap is varied or in CM MMF dist in space is made
sinusoidal. Fair degree of saturation is unavoidable, but high degree
of saturation should be avoided to get appx. Sinusoidal dist.
 Ideal sinusoidal wf is very difficult and therefore harmonics emf
will be generated. The harmonics can be easily eliminated from
voltage wf by properly designing wdg.
 Distribution: arm wdg not concentrated, distributed in diff. slots.
Mag of harmonics depends on dist. Factors. The Kd for harmonics
<< Kd for fund, relative magnitude of harmonics will be small.
 Chording: Short pitch coil, emf do not add algebraic, emf
Methods for generated depends on cos (nα/2), α- angle of chording,n order of
elimination of harmonics. Harmonic emf can be R or eliminated by proper value of
α.
harmonics  Skewing: slot harmonics E by skewing pole face
from  Fractional slot wdg: Slot harmonics emf R or E form output
voltage wf by using FSW.
generated
 Presently all Syn. Mach are FSW Kd for harmonics<< Kd for fund.
voltage  Large Lg: Lg-H, Rel- H, Mag of slot harmonics- R
 Flux pulsation –R – by no of s/pole arc- int +1/2.
 Armature design
 Armature winding
 Slot dimension
Revision  Elimination of harmonics

 Armature parameters, - Ra, Xl


 Design of rotor
next class  Height of pole
 Design of damper wdg
DESIGN OF SYNCHRONOUS MACHINE:
Output equation and design of main dimensions, Short Circuit Ratio (SCR)
and its significance, Length of air gap and shape of pole face.
ARMATURE DESIGN:
 Armature winding (Single layer and double layer), Number of armature
UNIT III slots, Slot dimensions, Length of mean turn, Calculation of armature
resistance and reactance.
Design of DESIGN OF FIELD SYSTEM:
synchronous  Design of magnetic circuit, Open circuit characteristic, Determination of
Machine full load field MMF, Design of field winding, Determination of direct and
quadrature axis synchronous reactance, Short circuit characteristics.
DESIGN OF TURBO ALTERNATORS:
 Main dimensions, Length of air gap, Stator & Rotor design. Design
considerations for low speed alternators and vertically operated alternator.
Computer programs and flow charts based on above topics.
 Discussed theory and formula related to MMF required
for armature per pole, MMF required for No-load field
Recap and MMF required for Air-gap
 Solved one numerical on Length of air-gap

SLO  Effects of length of air-gap on machine performance


 Estimation of magnetic circuit parameters such as Area
of pole body and dimension of pole body
𝐿𝑚𝑡𝑠
𝑆𝑡𝑎𝑡𝑜𝑟 𝐷𝐶 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑝𝑒𝑟 𝑝ℎ𝑎𝑠𝑒 𝑟𝑑.𝑐. = 𝜌. 𝑇𝑝ℎ .
𝑎𝑠
Where 𝐿𝑚𝑡 = 2𝐿 + 2.5𝜏 + 0.06𝐾𝑉 + 0.2 = Length of mean
turn of armature, m
𝑎𝑠 = area of stator conductor, 𝑚2
𝜌 = 𝑟𝑒𝑠𝑖𝑠𝑡𝑖𝑣𝑖𝑡𝑦, Ω − 𝑚𝑚2 Τ𝑚 = 0.021 𝑓𝑜𝑟 𝑐𝑜𝑝𝑝𝑒𝑟 𝑎𝑡 75°𝐶
Armature 2
Therefore, armature 𝐼 2 . 𝑅 loss = 3. 𝐼𝑝ℎ . 𝑟𝑑.𝑐.
Resistance 𝑁 2
𝐾𝑐(𝑎𝑣) = 1+(𝛼ℎ′ ) 4 .
9
Effective a.c. resistance 𝑟𝑎.𝑐. = 𝐾𝑐(𝑎𝑣) × 𝑟𝑑.𝑐.
𝐼𝑝ℎ ×𝑟𝑎.𝑐.
Per unit effective armature resistance =𝑅𝑎.𝑐. =
𝐸𝑝ℎ
2 𝜆𝑠
 Slot leakage reactance per phase 𝑥𝑠𝑠 = 8𝜋𝑓𝑇𝑝ℎ . 𝐿.
𝑝𝑞
Armature 2
 Overhang slot leakage reactance 𝑥0 = 8𝜋𝑓𝑇𝑝ℎ . 𝐿.
𝜆0
𝑝𝑞
Leakage
 Total stator slot leakage reactance 𝑥𝑙 = 𝑥𝑠𝑠 + 𝑥0
Reactance 𝐼𝑝ℎ .𝑥𝑙
 Per unit leakage reactance 𝑋𝑙 =
𝐸𝑝ℎ
1. Calculate a) size of armature wire b) the a.c. resistance of
each phase for a three phase 50 Hz, 8 pole star connected
Numerical synchronous generator having the following data:
Problem on Pole pitch 𝜏 =0.3 m, line current= 100A,
Armature slots per pole per phase 𝑞 = 3,
resistance and conductors per slot 𝑍𝑠 = 6,
reactance gross axial length 𝐿 = 0.3𝑚,
calculation lenght of active copper = 50% of total copper lenght ,
Average eddy current loss factor (𝐾𝑐 𝑎𝑣 = 1.3,
43000 𝑉𝑎
Given Data: 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝛿 = +
No. of poles = 8 𝑎𝑐 16
Frequency = 50 Hz 𝑤ℎ𝑒𝑟𝑒 𝛿 𝑖𝑠 𝑡ℎ𝑒 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝐴Τ𝑚𝑚2
Pole pitch 𝜏 =0.3 m, line 𝑎𝑐 = 𝑎𝑚𝑝𝑒𝑟𝑒 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠 𝑝𝑒𝑟 𝑚𝑒𝑡𝑟𝑒
current= 100A, 𝑣𝑎 = 𝑝𝑒𝑟𝑖𝑝ℎ𝑒𝑟𝑎𝑙 𝑠𝑝𝑒𝑒𝑑 𝑖𝑛 𝑚Τ𝑠𝑒𝑐
slots per pole per phase
𝑞 = 3, Solution:
conductors per slot 𝑍𝑠 = 𝜏×𝑃 0.3×8
6, Armature Diameter, D = 𝐷 = = = 0.7639 𝑚
𝜋 𝜋
gross axial length 𝐿 =
0.3𝑚, 2×50
Synchronous s𝑝𝑒𝑒𝑑, 𝑛𝑠 = = 12.5 𝑟. 𝑝. 𝑠.
lenght of active copper 8
= 50% of total copper lenght 𝑝𝑒𝑟𝑖𝑝ℎ𝑒𝑟𝑎𝑙 𝑠𝑝𝑒𝑒𝑑 , 𝑣𝑎 = 𝜋 × 𝐷 × 𝑛𝑠
Average eddy current = 𝜋 × 0.7639 × 12.5 = 30 𝑚/𝑠𝑒𝑐
loss factor (𝐾𝑐 𝑎𝑣 = 1.3
Total number of slots = 3 × 3 × 8 = 72
Given Data:
No. of poles = 8 Total number of conductors 𝑍 = 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 𝑝𝑒𝑟 𝑠𝑜𝑙𝑡 ×
Frequency = 50 Hz 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑙𝑜𝑡𝑠
Pole pitch 𝜏 =0.3 m, line 𝑍 = 72 × 6 = 432
current= 100A,
𝑍 6×72
slots per pole per phase 𝑞 Turns per phase 𝑇𝑝ℎ = = = 72
= 3, 6 6
conductors per slot 𝑍𝑠 = 6, Current in each conductor 𝐼𝑧 = 100 𝐴
gross axial length 𝐿 = (𝑎𝑠 𝑎𝑙𝑙 𝑐𝑜𝑖𝑙𝑠 𝑖𝑛 𝑎 𝑝ℎ𝑎𝑠𝑒 𝑎𝑟𝑒 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑒𝑑 𝑖𝑛 𝑠𝑒𝑟𝑖𝑒𝑠)
0.3𝑚,
lenght of active copper Now specific electric loading
= 50% of total copper lenght 𝐼𝑧 . 𝑍 100 × 432
Average eddy current 𝑎𝑐 = = = 18001.03 𝐴/𝑚
loss factor (𝐾𝑐 𝑎𝑣 = 1.3 𝜋. 𝐷 𝜋 × 0.7639
Current density in armature conductors,
Given Data: 43000 Va 43000 30
No. of poles = 8
δ= + = + = 4.26 AΤmm2
ac 16 18001.30 16
Frequency = 50 Hz 100
Pole pitch 𝜏 =0.3 m, line Area of armature conductor = = 23.474 mm2
4.26
current= 100A,
slots per pole per phase 𝑞 Active length of each turn = 2 × L = 2 × 0.3 = 0.6 m
= 3,
conductors per slot 𝑍𝑠 = 6,
Total length of a turn Lmt = 2 × 0.6 = 1.2 m
gross axial length 𝐿 = D.C. Resistance of each phase at 75℃
0.3𝑚,
lenght of active copper Lmts 1.2
rd.c. = ρ. Tph . = 0.021 × 72 × = 0.0773 Ω
= 50% of total copper lenght as 23.474
Average eddy current
loss factor (𝐾𝑐 𝑎𝑣 = 1.3
A.C resistance of each phase ra.c. = K c av × rd.c.
ra.c. = 1.3 × 0.0773 = 0.1004 Ω
No load field mmf per pole is equal to the product of
armature mmf per pole and short circuit ratio (SCR).
𝐴𝑇𝑓0 = 𝐴𝑇𝑎 × 𝑆𝐶𝑅
Where 𝐴𝑇𝑎 = 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑚𝑚𝑓 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒
𝐼𝑝ℎ 𝑇𝑝ℎ 𝐾𝑤
𝐴𝑇𝑎 = 2.7 ×
Estimation of 𝑝
𝐼𝑝ℎ 𝑇𝑝ℎ 𝐾𝑤
airgap length So 𝐴𝑇𝑓0 = 2.7 ×
𝑝
× 𝑆𝐶𝑅
The mmf required for airgap is approximately 80% of the no
load field mmf.
Hence , 𝐴𝑇𝑔 = 0.8 × 𝐴𝑇𝑓0 (1)
As we know, 𝐴𝑇𝑔 = 800000 × 𝐵𝑔 𝑙𝑔 𝐾𝑔 (2)
From equation (1) & (2),

0.8 × 𝐴𝑇𝑓0
𝑙𝑔 =
800000 × 𝐵𝑔 𝐾𝑔
Where 𝐵𝑔 = maximum flux density in airgap
Estimation of 𝐾𝑔 = gap contraction factor
airgap length If average gap density is given, then we can change the
formula as following:
𝐾𝑓 × 𝐴𝑇𝑓0
𝑙𝑔 =
1000000 × 𝐵𝑎𝑣 𝐾𝑔
𝐵𝑎𝑣
Where 𝐾𝑓 = 𝑓𝑖𝑒𝑙𝑑 𝑓𝑜𝑟𝑚 𝑓𝑎𝑐𝑡𝑜𝑟 =
𝐵𝑔
 Air gap coefficient or air gap contraction factor may be
assumed varying from 1.12 to 1.18.
 As a guide line, the approximate value of air gap length
can be expressed in terms of pole pitch.
Estimation of  For salient pole alternators:
airgap length 𝑙𝑔 = (0.012 to 0.016) x pole pitch
 For turbo alternators:
𝑙𝑔 = (0.02 to 0.026) x pole pitch
Why Air gap  Air gap length in synchronous machine is kept more as
length is more compared to induction machine due to the following
in Synchronous reasons:
Machine as 1. To Increase the Stability Limit of the Synchronous
Machine
compared to 2. Smaller Value of Voltage Regulation
Induction 3. Higher Value of Synchronizing Power
Machine?
 Longer air gap length means more reluctance offered to
the magnetic flux.
 More reluctance means lesser value of armature reaction
1. To Increase flux and hence lesser value of armature reaction
the Stability reactance (𝑋𝑎𝑟 ).
Limit of the  Apart from this, armature leakage flux will also reduce
due to longer air gap length. This in turn reduces the
Synchronous value of armature leakage reactance (𝑋𝑎𝑙 ).
Machine  The Synchronous Reactance 𝑋𝑠 = 𝑋𝑎𝑟 + 𝑋𝑎𝑙
1
 Now 𝑃𝛼 , so From this analysis, we can say that if 𝑋𝑠
𝑋𝑠
is decreases , the 𝑃𝑚𝑎𝑥 will increase.
1. A 500 KVA, 3.3 KV, 50 Hz, 600 r.p.m. 3 phase salient
pole alternator has 180 turns per phase.Estimate the
length of airgap if the average gap flux density is 0.54
𝑤𝑏Τ𝑚2 . Following data has to be considered in
design:
Numerical
the ratio of pole arc to pole pitch as considered as field
problem on form factor = 0.66.
estimation of The short circuit ratio is considered = 1.2.
airgap length The gap contraction factor (𝐾𝑔 ) = 1.15.
The winding factor 𝐾𝑤 = 0.955
The mmf required for airgap is approximately 80% of the
no load field mmf.
Given Data: Solution:
Q = 500 KVA, Synchronous speed 𝑛𝑠 =
600
= 10 𝑟𝑝𝑠
60
V = 3.3 KV , 2×50
Number of poles , 𝑃 = = 10
N=600 rpm , 10
f=50 Hz ,
3300
𝑇𝑝ℎ = 180, 𝐸𝑚𝑓 𝑝𝑒𝑟 𝑝ℎ𝑎𝑠𝑒 𝐸𝑝ℎ = = 1905.255 𝑉
3
𝐵𝑎𝑣 = 500×1000
0.54 𝑤𝑏Τ𝑚2, Current per phase , 𝐼𝑝ℎ = = 87.47 𝐴
3×1905.255
𝐾𝑓 = 𝜑 = 0.66,
𝐼𝑝ℎ 𝑇𝑝ℎ 𝐾𝑤
SCR=1.2, 𝐴𝑇𝑎 = 2.7 ×
𝑝
𝐾𝑔 = 1.15 ,
𝐾𝑤 = 0.955 and 87.47 × 180 × 0.955
𝐴𝑇𝑔 = 0.8𝐴𝑇𝑓0 𝐴𝑇𝑎 = 2.7 × = 4060.209 𝐴
10
Given Data:
Q = 500 KVA,
V = 33 KV , 𝐴𝑇𝑓0 = 𝐴𝑇𝑎 × 𝑆𝐶𝑅 = 4060.209 × 1.2 = 4872.25 𝐴
N=600 rpm , 𝐵𝑎𝑣 0.54
f=50 Hz , Maximum airgap density 𝐵𝑔 = = = 0.818 𝑤𝑏Τ𝑚2
𝐾𝑓 0.66
𝑇𝑝ℎ = 180, MMF for airgap ,𝐴𝑇𝑔 = 800000 × 𝐵𝑔 𝑙𝑔 𝐾𝑔
𝐵𝑎𝑣 =
0.54 𝑤𝑏Τ𝑚2, 𝐴𝑇𝑔 = 0.8𝐴𝑇𝑓0 = 0.8 × 4872.25 = 3897.80 𝐴
𝐾𝑓 = 𝜑 = 0.66,
3987.8
SCR=1.2, Length of air gap , 𝑙𝑔 = = 5.179 × 10−3 𝑚
800000×0.818×1.15
𝐾𝑔 = 1.15 , 𝑙𝑔 = 5.179 𝑚𝑚
𝐾𝑤 = 0.955 and
𝐴𝑇𝑔 = 0.8𝐴𝑇𝑓0
 The following is the design data available for a 1250 KVA, 3
phase , 50 Hz, 3300 V, star connected, 300 rpm, alternator of
salient pole type:
Stator bore D = 1.9 m, Stator core length L= 0.335 m, Pole
arc/pole pitch = 0.66, turns per phase= 150, single layer with 5
conductors per slot, Short circuit ratio = 1.2. Assume that the
Numerical distribution of flux is rectangular under the pole arc with zero
problem on values in the interpolar region. Calculate:
Armature mmf a) Specific Magnetic Loading
per pole b) Armature mmf per pole
c) Gap density over pole arc
d) Air-gap length
MMF required for air-gap is 0.88 of no load field mmf and the
gap contraction factor is 1.15.
Solution:
𝑇𝑝ℎ = 150 Total Stator conductors = Z = 6. 𝑇𝑝ℎ = 6 × 150 = 900
𝑄 = 1250 𝐾𝑉𝐴 𝑍 900
Total number of stator slots = = = 180
V= 3300 V, 𝑍𝑠 5
N = 300 r.p.m. Synchronous speed, 𝑛𝑠 =
300
= 5 𝑟. 𝑝. 𝑠.
60
D = 1.9 m, 2.𝑓 2×50
L = 0.335 m, Number of Pole, 𝑝 = = = 20
𝑛𝑠 5
𝜑 = 0.66, 180
SCR = 1.2 Slot per pole per phase , 𝑞 = =3
3×20
𝑍𝑠 = 5, 𝛽=
180
=
180
= 20°
𝑆𝑙𝑜𝑡Τ𝑝𝑜𝑙𝑒 (180Τ20)
𝐾𝑔 = 1.15,
3×20°
𝐴𝑇𝑔 = 0.88𝐴𝑇𝑓0 𝑠𝑖𝑛 2
Distribution factor, 𝐾𝑑 = 20°
= 0.9597 ≅ 0.96
3 sin( 2 )
𝑇𝑝ℎ = 150 Pitch Factor 𝐾𝑝 = 1 as winding is full pitch coils
𝑄 = 1250 𝐾𝑉𝐴 Hence, Winding Factor 𝐾𝑤 = 𝐾𝑝 × 𝐾𝑑
V= 3300 V, 𝐾𝑤 = 0.96 × 1 = 0.96
N = 300 r.p.m. 𝐸𝑝ℎ = 4.44𝑓𝜑𝑇𝑝ℎ 𝐾𝑤
𝐸𝑝ℎ 1905.255
D = 1.9 m, ∅= =
4.44 × 𝑓 × 𝑇𝑝ℎ × 𝐾𝑤 4.44 × 50 × 150 × 0.96
= 0.0595 𝑤𝑏
L = 0.335 m,
𝜑 = 0.66, 𝜋. 𝐷 𝜋 × 1.9
SCR = 1.2 𝜏= = = 0.2984 m
𝑃 20
𝑍𝑠 = 5, 𝜋. 𝐷. 𝐿
𝐴𝑟𝑒𝑎 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒 𝐴𝑝 = = 𝜏. 𝐿 = 0.2984 × 0.335 = 0.09996 𝑚
𝐾𝑔 = 1.15, 𝑝
∅𝑝 0.0595
𝐴𝑇𝑔 = 0.88𝐴𝑇𝑓0 Specific Magnetic Loading , 𝐵𝑎𝑣 =
𝐴𝑝
=
0.09996
= 0.595 𝑤𝑏/𝑚2
𝑩𝑎𝑣 0.595
Maximum Gap density, 𝐵𝑔 = = = 0.9015 𝑤𝑏ൗ𝑚2
𝑇𝑝ℎ = 150 𝜑 0.66
𝑄 = 1250 𝐾𝑉𝐴 Current per phase 𝐼𝑝ℎ =
𝑄×1000
=
1250×1000
= 218.6933 𝐴
3.𝐸𝑝ℎ 3×1905.255
V= 3300 V,
𝐴𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑚𝑚𝑓 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒,
N = 300 r.p.m. 218.6933×150×0.96
D = 1.9 m, 𝐴𝑇𝑎 = 2.7 × = 4251.3977 𝐴
20
L = 0.335 m, No load field mmf, 𝐴𝑇𝑓0 = 𝑆𝐶𝑅 × 𝐴𝑇𝑎 = 1.2 × 4251.3977=
𝜑 = 0.66, 𝐴𝑇𝑓0 = 5101.6773 𝐴
SCR = 1.2
𝑍𝑠 = 5, Mmf required for air-gap, 𝐴𝑇𝑔 = 0.88 × 𝐴𝑇𝑓0
𝐴𝑇𝑔 = 0.88 × 5101.6773 = 4489.47 𝐴
𝐾𝑔 = 1.15,
4489.47
𝐴𝑇𝑔 = 0.88𝐴𝑇𝑓0 Length of air-gap, 𝑙𝑔 =
800000×0.9015×1.15
= 0.005413 𝑚
𝑙𝑔 = 5.413 𝑚𝑚
Flux in pole body ,
∅𝑝 = leakage co𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 × 𝑢𝑠𝑒𝑓𝑢𝑙 𝑓𝑙𝑢𝑥 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒
The value of leakage coefficient lies between 1.15 to 1.2.
∅𝑝
Area of cross-section of pole body, 𝐴𝑝 =
𝐵𝑝

Design of Here 𝐵𝑝 = 𝐹𝑙𝑢𝑥 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝑝𝑜𝑙𝑒 𝑏𝑜𝑑𝑦


The permissible value of 𝐵𝑝 can be considered as 1.5 to 1.7
Rotor 𝑤𝑏
ൗ𝑚2 .
For rectangular pole, 𝐴𝑝 = 0.98𝐿𝑝 𝑏𝑝
Where 𝐿𝑝 =Axial length of poles
The axial length of poles can be considered is equal to gross
stator core length L. The stacking factor for pole laminations is
taken as 0.98.
Types of pole
body
𝜋
For circular poles, 𝐴𝑝 = . 𝑏𝑝 2
4
Radial length of pole, ℎ𝑝𝑙 = ℎ𝑓 + ℎ1 + 0.02
Where,
Design of ℎ𝑓 is called as height of field winding.
Rotor ℎ1 is called height of pole shoe
Height of field winding can be estimated as with the help
of field mmf.
Field mmf can be calculated using following steps:
1) Find armature mmf per pole, 𝐴𝑇𝑎 .
2) Find no load field mmf, 𝐴𝑇𝑓0 .
Calculation of 3) Draw 𝑜𝑎 = 𝐴𝑇𝑓0 .
full load field 4) Draw 𝑎𝑏 = 𝐴𝑇𝑎 𝑎𝑡 𝑎𝑛 𝑎𝑛𝑔𝑙𝑒 𝑜𝑓 90 − 𝜙 𝑡𝑜 𝑜𝑎.
𝑤ℎ𝑒𝑟𝑒 𝑐𝑜𝑠𝜙 = power factor lagging.
mmf 𝑎𝑐
5) Cut off 𝑎𝑐 such that = 𝐾𝑟 , where 𝐾𝑟 =
𝑎𝑏
𝑐𝑟𝑜𝑠𝑠 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡.
The value of 𝐾𝑟 depends upon the ration of pole arc to pole
pitch. The value of 𝐾𝑟 can be considered from fig (a).
 Phasor Diagram with resistance and leakage reactance of
armature winding neglected
Calculation of
full load field
mmf
6) Join 𝑜𝑐 and extend it. Drop a perpendicular from b on
extended oc, cutting it at d.
𝑜𝑑 = 𝑓𝑖𝑒𝑙𝑑 𝑚𝑚𝑓 𝑎𝑡 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑤𝑖𝑡ℎ 𝑝𝑜𝑤𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 𝑐𝑜𝑠𝜙
𝑙𝑎𝑔𝑔𝑖𝑛𝑔
𝐹𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑓𝑖𝑒𝑙𝑑 𝑚𝑚𝑓 𝐴𝑇𝑓𝑙
Calculation of 7) Copper area of field winding = =
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝛿𝑓
Height of 8) Height of winding , ℎ𝑓 =
𝑡𝑜𝑡𝑎𝑙 𝑤𝑖𝑛𝑑𝑖𝑛𝑔 𝑎𝑟𝑒𝑎
𝑑𝑓
winding
The depth of winding can be calculated according to pole
pitch.
9) The height of winding can be calculated using following
𝐴𝑇𝑓𝑙 ×10−4
formula also: ℎ𝑓 =
𝑠𝑓 𝑞𝑓 𝑑𝑓
Here
𝑆𝑓 = 𝑐𝑜𝑝𝑝𝑒𝑟 𝑠𝑝𝑎𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
𝑞𝑓 = 𝑙𝑜𝑠𝑠 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑠𝑢𝑟𝑓𝑎𝑐𝑒, 𝑤ൗ 2
𝑚
Height of pole body, ℎ𝑝 = ℎ𝑓 + 0.02
Calculation of The ratio of radial length of pole, ℎ𝑝𝑙 to pole pitch, 𝜏 is
Height of generally equal to 0.3 to 1.5.
winding For smaller number of poles and larger pole pitch, the
ratio must be considered as high value.
For larger number of poles and small value of pole pitch,
the ratio must be considered as low value.
 Solved Example for estimation of armature MMF per
pole and length of air-gap
Summary  Discussed about design of magnetic field system for
salient pole alternator
 Height of field winding by calculating full load field
MMF

 Will solve numerical problem on height of field winding


Next Session
 Will discuss design of damper winding and its
importance
 Design of damper winding
 Height of pole shoe
 Pole profile drawing
 Magnetic circuit design
 OCC
 Determination of full load field mmf
Department of
Electrical Engineering

Unit- III : DESIGN OF


SYNCHRONOUS
MACHINE
Design of AC
Machine
(3170909)
Design of Field Winding

Dr. Amit Ved


DESIGN OF SYNCHRONOUS MACHINE:
Output equation and design of main dimensions, Short Circuit Ratio (SCR)
and its significance, Length of air gap and shape of pole face.
ARMATURE DESIGN:
 Armature winding (Single layer and double layer), Number of armature
UNIT III slots, Slot dimensions, Length of mean turn, Calculation of armature
resistance and reactance.
Design of DESIGN OF FIELD SYSTEM:
synchronous  Design of magnetic circuit, Open circuit characteristic, Determination of
Machine full load field MMF, Design of field winding, Determination of direct and
quadrature axis synchronous reactance, Short circuit characteristics.
DESIGN OF TURBO ALTERNATORS:
 Main dimensions, Length of air gap, Stator & Rotor design. Design
considerations for low speed alternators and vertically operated alternator.
Computer programs and flow charts based on above topics.

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


 Calculation of total MMF for different parts of magnetic
Recap circuit
 Solved numerical problem on calculation of MMF

SLO  Design of field winding


 Numerical problem of design of field winding

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


 The total MMF is divided into following parts:
1. MMF for air-gap
2. MMF for armature teeth
Calculation of 3. MMF for core
total MMF 4. MMF for poles
5. MMF for yoke
The total MMF is calculated as:
𝐴𝑇𝑓0 = 𝐴𝑇𝑔 + 𝐴𝑇𝑡 + 𝐴𝑇𝑐 + 𝐴𝑇𝑝 + 𝐴𝑇𝑦

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


 Wire wound coils are generally used for machines with a
small number of poles.
 The field coils of small alternators having large number
of poles are wound with glass covered rectangular strips.
 For machines with class B insulation, asbestos of 0.18
Design of field mm thickness is carried out for interturn insulation.
winding  For 2 layers the total thickness of interturn insulation
will be 0.36 mm.
 Flanges made of bakelized asbestos board are used at 10
mm thickness.
 Field coil flanges are the insulation between a field coil
and a pole shoe or between a field coil and the member
carrying the pole body.

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


 For machines designed with class F insulation, the
interturn insulation consists of 3 layers of 0.18 mm
thick.
 The pole body insulation is of epoxy glass laminates
Design of field with 4 mm thickness.
winding  The length of mean turn of field winding can be
calculated as:
𝐿𝑚𝑡𝑓 = 2. 𝐿𝑚 + 𝜋(𝑏𝑝 + 0.01 + 𝑑𝑓 )
Where 𝐿𝑚 = 0.9. 𝐿

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


 Following steps are required to design of field winding:
1. In order to design of field winding, the exciter voltage
varies from 50 V to 400 V specifically depending
upon design specifications as per customer
requirement
Design of field
2. The field winding should be designed for a voltage
winding from to 15% to 20 % less than exciter voltage to
allow variations in reluctance of magnetic field.
Let 𝑉𝑒 is the exciter voltage,
0.8 𝑡𝑜 0.85 𝑉𝑒
Voltage across each field coil , 𝐸𝑓 = (1)
𝑝

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


3. As we know ,
Height of pole body, ℎ𝑝𝑙 = ℎ𝑓 + 0.02 + ℎ1
Height of field winding, ℎ𝑓 = ℎ𝑝𝑙 − ℎ1 − 0.02 (2)
4. Depth of field winding:
Design of field Depth of field winding can be calculated according to
winding length of pole pitch.
Pole Pitch (mm) Winding Depth (mm)
100 25
200 35
400 45

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


5. Voltage across each field coil,
𝐸𝑓 = 𝐼𝑓 𝑅𝑓 (3)
Now the resistance of field winding ,𝑅𝑓 can be calculated
as:
Design of field 𝐿𝑚𝑡𝑓
winding 𝑅𝑓 = 𝜌. . 𝑇𝑓 (4)
𝑎𝑓

𝑇𝑓 =Number of turns in each field coil


𝑎𝑓 = area of each field coil winding
𝜌= specific resistance of copper = 0.021 Ω − 𝑚𝑚2 /𝑚

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


6. From equation (3) & (4), Area of each filed winding
conductor can be calculated as,
𝐿𝑚𝑡𝑓
𝐸𝑓 = 𝜌. . 𝑇𝑓 𝐼𝑓
𝑎𝑓
𝐿𝑚𝑡𝑓
𝐸𝑓 = 𝜌. . 𝐴𝑇𝑓𝑙
𝑎𝑓
Design of field 𝜌.𝐴𝑇𝑓𝑙 .𝐿𝑚𝑡𝑓
winding 𝑎𝑓 =
𝐸𝑓
(5)

7. The value of field current can be calculated by


assuming suitable value of current density as per
design data. The value of current density for field
winding conductors can be considered from 3 to 4
𝐴Τ
𝑚𝑚2 .

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


Field current, 𝐼𝑓 = 𝑎𝑓 × 𝛿𝑓 (6)
8. Number of turns in field winding ,
𝐴𝑇𝑓𝑙
𝑇𝑓 = (7)
𝐼𝑓

9. Copper loss in each field coil at 75℃,


Design of field 𝐿𝑚𝑡𝑓
2 2
winding 𝑄𝑓 = 𝐼𝑓 . 𝑅𝑓 = 𝐼𝑓 . 𝜌. . 𝑇𝑓
𝑎𝑓

This loss causes temperature rise in field coils. We have to


maintain the temperature rise within limits.
Dissipating surface of the coil,
𝑆 = 2. 𝐿𝑚𝑡 (ℎ𝑓 + 𝑑𝑓 ) (8)

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


10. Cooling coefficient to rotating field coils,
0.08 𝑡𝑜 0.12
𝑐𝑓 = (9)
1+0.1𝑣𝑎
11. Temperature rise,
𝑄𝑓 .𝑐𝑓
𝜃= (10)
Design of field 𝑆
If the temperature rise of the coil exceeds the limit, depth
winding of field winding must be varied according to range.
The change in depth of field winding will change the
current density and the total losses can be varied.
The increasing limit of depth of field winding also
provides better cooling and provides low temperature rise.

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


 The field coils of salient pole alternator are wound with
a single layer winding of bare copper strip of 30 mm
deep, with separating insulation 0.15 mm thick.
Numerical Determine a suitable winding length, number of turns,
and thickness od conductor to develop a MMF of 15000
Problem on A with a potential difference of 5 V per coil and with a
design of field loss of 1500 𝑊 Τ𝑚2 of total coil surface. The mean
length of turn is 1.5 m. The resistivity of copper is 0.021
winding Ω − 𝑚𝑚2 /𝑚.

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


We have to find ,
𝜌.𝐴𝑇𝑓𝑙 .𝐿𝑚𝑡𝑓
Given that: 1. Area of field winding conductor, 𝑎𝑓 =
𝐸𝑓
𝐴𝑇𝑓𝑙 = 15000𝐴
𝑎𝑓
𝐿𝑚𝑡𝑓 = 1.5 𝑚 2. Height of field winding conductor ℎ𝑓𝑝𝑒𝑟 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 =
𝑑𝑓
𝐸𝑓 = 5 𝑉
𝑄𝑓
𝑑𝑓 = 30 𝑚𝑚 3. Current in field winding , 𝐼𝑓 =
𝐸𝑓
Specific loss coefficient,
𝑞𝑓 = 1500 𝑤Τ𝑚𝑚2 4. Turns of field winding, 𝑇𝑓 =
𝐴𝑇𝑓𝑙

𝜌 = 0.021Ω − 𝑚𝑚2/𝑚 𝐼𝑓

5. Total height of field winding, ℎ𝑓 = ℎ𝑓𝑝𝑒𝑟 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 × 𝑇𝑓

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


 Solution:
𝜌.𝐴𝑇𝑓𝑙 .𝐿𝑚𝑡𝑓
Given that: Area of field winding, 𝑎𝑓 =
𝐸𝑓
𝐴𝑇𝑓𝑙 = 15000𝐴 0.021×15000×1.5
𝐿𝑚𝑡𝑓 = 1.5 𝑚 𝑎𝑓 = = 94.5 𝑚𝑚2
5
𝐸𝑓 = 5 𝑉 𝑎𝑓
Height of field winding conductor ℎ𝑓𝑝𝑒𝑟 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 =
𝑑𝑓 = 30 𝑚𝑚 𝑑𝑓
Specific loss coefficient, 94.5
ℎ𝑓𝑝𝑒𝑟 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 = = 3.15 𝑚𝑚
𝑞𝑓 = 1500 𝑤Τ𝑚𝑚2 30
𝜌 = 0.021Ω − 𝑚𝑚2/𝑚 Modified area of field winding conductor ,
𝑎𝑓𝑚𝑜𝑑. = 30 × 3 = 90 𝑚𝑚2

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


Total Heat dissipating surface area,
𝑆 = 2. 𝐿𝑚𝑡 (ℎ𝑓 + 𝑑𝑓 )
Given that:
𝐴𝑇𝑓𝑙 = 15000𝐴 𝑆 = 2 × 1.5. ℎ𝑓 + 0.03 = 3. ℎ𝑓 + 0.09 𝑚2 (1)
𝐿𝑚𝑡𝑓 = 1.5 𝑚 Total loss in winding for dissipation , 𝑄𝑓
𝐸𝑓 = 5 𝑉
𝑑𝑓 = 30 𝑚𝑚 𝑄𝑓 = 𝑞𝑓 × 𝑆
Specific loss coefficient, 𝑄𝑓 = 1500 × 3. ℎ𝑓 + 0.09 = 4500. ℎ𝑓 + 135 𝑊 (2)
𝑞𝑓 = 1500 𝑤Τ𝑚𝑚2 𝑄𝑓
𝜌 = 0.021Ω − 𝑚𝑚2/𝑚 Current in field winding , 𝐼𝑓 =
𝐸𝑓
4500.ℎ𝑓 +135
𝐼𝑓 = = 900. ℎ𝑓 + 27 𝐴 (3)
5

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


Total MMF developed in field winding, 𝐴𝑇𝑓𝑙
Given that: 𝐴𝑇𝑓𝑙 = 𝐼𝑓 × 𝑇𝑓
𝐴𝑇𝑓𝑙 = 15000𝐴 𝐴𝑇𝑓𝑙 = (900. ℎ𝑓 + 27) × 𝑇𝑓
𝐿𝑚𝑡𝑓 = 1.5 𝑚
15000 = 900. ℎ𝑓 𝑇𝑓 + 27. 𝑇𝑓 (4)
𝐸𝑓 = 5 𝑉
𝑑𝑓 = 30 𝑚𝑚 Height occupied by each conductor = 3.15+0.15 = 3.3 mm
Specific loss Total Height of winding , ℎ𝑓 = 3.3 × 10−3 × 𝑇𝑓
coefficient, Replacing the value of ℎ𝑓 in terms of 𝑇𝑓 in eqn (4), we get
𝑞𝑓 = 1500 𝑤Τ𝑚𝑚2
𝜌= 0.021Ω − 𝑚𝑚2/𝑚 15000 = 2.970. 𝑇𝑓 2 + 27. 𝑇𝑓 (5)
Considering equation (5), the roots can be found using ,

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


Given that: −𝑏± 𝑏2 −4𝑎𝑐
𝐴𝑇𝑓𝑙 = 15000𝐴 𝛼, 𝛽 =
2.𝑎
𝐿𝑚𝑡𝑓 = 1.5 𝑚 Here from equation (5), a = 2.97 , b = 27 & c = -15000
𝐸𝑓 = 5 𝑉 So , the number of turns of field winding, 𝑇𝑓
𝑑𝑓 = 30 𝑚𝑚
Specific loss 𝑇𝑓 = 66.66 ≅ 66
coefficient, Total height of field winding, ℎ𝑓
𝑞𝑓 = 1500 𝑤Τ𝑚𝑚2 ℎ𝑓 = 66 × 3.3 = 217.8 𝑚𝑚
𝜌= 0.021Ω − 𝑚𝑚2/𝑚

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


 Discussed design of field winding
 Solved one numerical problem on design of field
Summary winding

 Determination of direct and quadrature axis synchronous


reactance
 Will solve one numerical problem on determination of
Next Session direct and quadrature axis synchronous reactance

28-10-2023 Design of Salient Pole Alternator: Design of Field winding


Recap  Numerical problem of design of field winding.
 Determination of direct and quadrature axis reactance

SLO  Numerical Problem on direct & quadrature reactance


 Design of turbo alternator

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 127


 The magnetising reactance per phase of a cylindrical
rotor machine with uniform airgap and with three phase
winding is calculated as:
7.54𝑓𝑇𝑝ℎ 2 .𝐾𝑤 2 .𝐷𝐿
𝑥𝑚 = × 10−6 (1)
Determination 𝑝2 .𝑙𝑔 .𝐾𝑔

of Direct & Per unit magnetising reactance,


𝐼𝑝ℎ .𝑥𝑚
Quadrature 𝑋𝑚 =
𝐸𝑝ℎ
(2)
Axis Reactance The armature reactance in the direct and quadrature axis
for salient pole alternators can be calculated as ;
Per unit direct axis armature reaction reactance,
𝑋𝑎𝑑 = 𝐴𝑑1 . 𝑋𝑚 (3)

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 128


Here,
𝐴𝑑1 = 𝑓𝑙𝑢𝑥 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑓𝑜𝑟 𝑑𝑖𝑟𝑒𝑐𝑡 𝑎𝑥𝑖𝑠
𝐴𝑑1 = 𝜌𝑑 × 𝐴1 (4)
Determination 𝜌𝑑 = 𝑟𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑑𝑖𝑟𝑒𝑐𝑡 𝑎𝑥𝑖𝑠 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑚𝑚𝑓
of Direct & 𝛼+sin 𝛼
𝜌𝑑 =
Quadrature 4.sin 𝛼Τ2
𝐵𝑚1
Axis Reactance 𝐴1 =
𝐵𝑔

Per Unit quadrature axis armature reactance, 𝑋𝑎𝑞


𝑋𝑎𝑞 = 𝐴𝑞1 × 𝑋𝑚

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 129


Here, 𝐴𝑞1 = Flux distribution coefficient for quadrature
axis
4𝜓+1 sin 𝜓𝜋
𝐴𝑞1 = −
5 𝜋
Determination
Where 𝜓 = ratio of pole arc to pole pitch
of Direct &
Per unit value of unsaturated synchronous reactance for
Quadrature the two axes,
Axis Reactance Direct axis synchronous reactance, 𝑋𝑑 = 𝑋𝑙 + 𝑋𝑎𝑑
Quadrature axis synchronous reactance, 𝑋𝑞 = 𝑋𝑙 + 𝑋𝑎𝑞
𝑋𝑙 = per unit leakage reactance

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 130


1. A 2000KVA, 32 pole, 50 Hz, 2200 V, star connected
salient pole alternator has the following design data:
Numerical Stator Bore = 2.5 m, Core Length = 0.5 m , Turns per
Problem on phase = 250 , winding factor = 0.955 , air gap length = 10
mm , air gap contraction factor = 1.15 , ratio of pole arc to
direct and pole pitch = 0.65 , ratio of amplitude of fundamental 0f
quadrature maximum gap density to gap flux density = 1.07 , per unit
leakage reactance = 0.15 Ω.
synchronous Determine the direct and quadrature axis reactance.
reactance

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 131


Given that: Solution:
Q = 2000 KVA
7.54𝑓𝑇𝑝ℎ 2 .𝐾𝑤 2 .𝐷𝐿
P = 32 𝑥𝑚 = × 10−6
𝑝2 .𝑙𝑔 .𝐾𝑔
f = 50 Hz
V = 2200 V 7.54×50×2502 ×0.9552 ×2.5×0.5
𝑥𝑚 = × 10−6
322 ×0.01×1.15
D = 2.5 m
L = 0.5 m 𝑥𝑚 = 2.281 Ω
𝑇𝑝ℎ = 250 Voltage per phase ,
𝐾𝑤 = 0.955 2200
𝑙𝑔 = 0.01 𝑚 𝐸𝑝ℎ = = 1270.17 𝑉
3
𝐾𝑔 = 1.15 𝑄×1000
Current per phase, 𝐼𝑝ℎ =
𝜓 = 0.65 3.𝐸𝑝ℎ
𝐴1 = 1.07 2000×1000
𝐼𝑝ℎ = = 524.864 𝐴
𝑋𝑙 = 0.65 Ω 3×1270.17

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 132


Given that: 𝐼𝑝ℎ .𝑥𝑚
Q = 2000 KVA Per unit magnetising reactance, 𝑋𝑚 =
𝐸𝑝ℎ
P = 32 2.281×524.864
f = 50 Hz 𝑋𝑚 = = 0.9425 Ω
1270.17
V = 2200 V
Angle embrace by pole arc, 𝛼 = 𝜓. 𝜋
D = 2.5 m
L = 0.5 m 𝛼 = 0.65 × 𝜋 = 2.042 𝑟𝑎𝑑 = 117°
𝑇𝑝ℎ = 250 𝐴𝑑1 = 𝑓𝑙𝑢𝑥 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑓𝑜𝑟 𝑑𝑖𝑟𝑒𝑐𝑡 𝑎𝑥𝑖𝑠
𝐾𝑤 = 0.955 𝐴𝑑1 = 𝜌𝑑 × 𝐴1
𝑙𝑔 = 0.01 𝑚 𝛼+sin 𝛼
𝜌𝑑 =
𝐾𝑔 = 1.15 4.sin 𝛼Τ2
𝜓 = 0.65 𝜌𝑑 =
2.042+sin 117
= 0.8599
𝐴1 = 1.07 4.sin 117Τ2
𝑋𝑙 = 0.65 Ω
28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 133
Given that: 𝐴𝑑1 = 𝜌𝑑 × 𝐴1
Q = 2000 KVA 𝐴𝑑1 = 0.8599 × 1.07 = 0.92
P = 32
f = 50 Hz Per unit direct axis armature reaction reactance,
V = 2200 V 𝑋𝑎𝑑 = 𝐴𝑑1 . 𝑋𝑚
D = 2.5 m
𝑋𝑎𝑑 = 0.92 × 0.9425 = 0.8671 Ω
L = 0.5 m
𝑇𝑝ℎ = 250 Per Unit quadrature axis armature reactance, 𝑋𝑎𝑞
𝐾𝑤 = 0.955 𝑋𝑎𝑞 = 𝐴𝑞1 × 𝑋𝑚
𝑙𝑔 = 0.01 𝑚
4𝜓+1 sin 𝜓𝜋
𝐾𝑔 = 1.15 𝐴𝑞1 =
5

𝜋
𝜓 = 0.65 4×0.65+1 sin 0.65×𝜋
𝐴1 = 1.07 𝐴𝑞1 = − = 0.72 − 0.26 = 0.46
5 𝜋
𝑋𝑙 = 0.65 Ω

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 134


Given that:
Q = 2000 KVA
𝑋𝑎𝑞 = 𝐴𝑞1 × 𝑋𝑚
P = 32
f = 50 Hz 𝑋𝑎𝑞 = 0.46 × 0.9425 = 0.4355 Ω
V = 2200 V
D = 2.5 m Direct axis synchronous reactance,
L = 0.5 m 𝑋𝑑 = 𝑋𝑙 + 𝑋𝑎𝑑
𝑇𝑝ℎ = 250 𝑋𝑑 = 0.65 +0.8671 = 1.5171 Ω
𝐾𝑤 = 0.955
𝑙𝑔 = 0.01 𝑚 Quadrature axis synchronous reactance,
𝐾𝑔 = 1.15 𝑋𝑞 = 𝑋𝑙 + 𝑋𝑎𝑞
𝜓 = 0.65 𝑋𝑞 = 0.65 + 0.4355 = 1.0855 Ω
𝐴1 = 1.07
𝑋𝑙 = 0.65 Ω

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 135


 The value of specific loading for conventionally cooled
generators are:
𝐵𝑎𝑣 = 0.54 𝑡𝑜 0.65 𝑊𝑏
ൗ𝑚2
𝑎𝑐 = 50000 𝑡𝑜 75000 𝐴/𝑚
 The value of specific loading for water cooled
Design of generators are:
turbo-alternator 𝐵𝑎𝑣 = 0.54 𝑡𝑜 0.62 𝑊𝑏
ൗ𝑚2
𝑎𝑐 = 180,000 𝑡𝑜 200,000 𝐴/𝑚
 In design of turbo-alternator, the value of stator bore is
limited by the peripheral speed.
 The maximum allowable peripheral speed is 175 m/sec.

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 136


 Estimate the diameter, core length, size and number of
conductor, number of slots for stator of a 25 MVA, 13.8
kV, 50 Hz, 2 pole star connected turbo alternator, 60°
Design of phase spread of distribution factor as 0.955 with
following data:
turbo- 𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2
alternator: 𝑎𝑐 = 54000 𝐴/𝑚
Calculation of Current density, 𝛿 = 5 𝐴Τ𝑚2
Main Peripheral speed ,𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐
Dimensions The winding should be arranged to eliminate 5𝑡ℎ
harmonics.

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 137


Solution:
2.𝑓
Given that: Synchronous speed, 𝑛𝑠 =
𝑝
Q = 25000 KVA 2×50
𝑛𝑠 = = 50 𝑟𝑝𝑠
V = 13800 V 2
f = 50 Hz 𝑣𝑎 = 𝜋. 𝐷. 𝑛𝑠
p=2 120
𝐷= = 0.7639 𝑚
𝜋×50
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2
To eliminate the 5th harmonics, the coils should be
𝑎𝑐 = 54000 𝐴/𝑚 chorded by an angle:
𝛿 = 5 𝐴Τ𝑚2 180
𝛼= = 36°
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 5
𝐾𝑑 = 0.955 𝐾𝑝 = cos 𝛼 Τ2
𝐾𝑝 = cos 18 = 0.951

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 138


The winding factor, 𝐾𝑤 = 𝐾𝑑 × 𝐾𝑝
Given that: 𝐾𝑤 = 0.951 × 0.955 = 0.908
Q = 25000 KVA
V = 13800 V Output coefficient, 𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 × 10−3
f = 50 Hz 𝐶0 = 11 × 0.55 × 54000 × 0.908 × 10−3
p=2 𝐶0 = 294.6436 3
KVA
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 𝑚 −𝑟𝑝s
𝑄
𝑎𝑐 = 54000 𝐴/𝑚 2
𝐷 .𝐿 =
𝐶0 .𝑛𝑠
𝛿 = 5 𝐴Τ𝑚2 25000
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 𝐷2 . 𝐿 = = 1.6855 𝑚3
294.6436×50
𝐾𝑑 = 0.955 𝐿=
1.6855
= 2.888 𝑚
0.76392

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 139


Flux per pole, 𝜙 = 𝐵𝑎𝑣 . 𝜏. 𝐿
Given that: 𝜋.𝐷 𝜋×0.7639
Q = 25000 KVA Pole pitch, 𝜏 = = = 1.199 𝑚
𝑝 2
V = 13800 V
Flux per pole, 𝜙 = 0.55 × 1.199 × 2.888 = 1.904 𝑤𝑏
f = 50 Hz 13800
p=2 Voltage per phase, 𝐸𝑝ℎ = = 7967.433 𝑉
3
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 Turns per phase,
𝑎𝑐 = 54000 𝐴/𝑚 7967.433
𝛿 = 5 𝐴Τ𝑚2 𝑇𝑝ℎ = = 20.75 ≅ 20
4.44×50×1.904×0.908
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 Total Number of Stator conductors, 𝑍 = 6. 𝑇𝑝ℎ
𝐾𝑑 = 0.955 𝑍 = 6 × 20 = 120

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 140


𝑄×1000
Given that: Current Per phase, 𝐼𝑝ℎ =
3𝐸𝑝ℎ
Q = 25000 KVA
25000×1000
V = 13800 V 𝐼𝑝ℎ = = 1045.92 𝐴
3×7967.433
f = 50 Hz As the current is more than 400 A, so taking number of
p=2 parallel path = 2
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 1045.92
Current in each conductor, 𝐼𝑧 = = 522.96 𝐴
𝑎𝑐 = 54000 𝐴/𝑚 2
𝛿 = 5 𝐴Τ𝑚2 Area of each Conductor, 𝑎𝑧 =
𝐼𝑧
𝛿
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 522.96
𝐾𝑑 = 0.955 𝑎𝑧 = = 104.592 𝑚𝑚2
5

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 141


 A 3000 r.p.m, 50 Hz, 3 phase turbo alternator has a core
length of 0.94 m. The average gap density is
Design of 0.65 𝑊𝑏ൗ𝑚2 and the ampere conductor per metre is
turbo- 60000 A/m. The peripheral speed is 100 m/sec and the
length of air-gap is 15 mm. find the KVA output of the
alternator: machine when the coils are:
Calculation of i. Full pitch
Main ii. Chorded by 1/3 pole pitch
Dimensions The winding can be taken as infinitely distributed with a
phase spread as 60°.

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 142


 Solved numerical problems on determination of direct
and quadrature axis synchronous reactance.
Summary  Introduced design of turbo alternator in terms of main
dimension
 Discussed stator design of turbo alternator

 Will discuss rotor design of turbo alternator


Next Session
 Will introduce all types of losses

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 143


DESIGN OF SYNCHRONOUS MACHINE:
Output equation and design of main dimensions, Short Circuit Ratio (SCR)
and its significance, Length of air gap and shape of pole face.
ARMATURE DESIGN:
 Armature winding (Single layer and double layer), Number of armature
slots, Slot dimensions, Length of mean turn, Calculation of armature
UNIT III resistance and reactance.
Design of DESIGN OF FIELD SYSTEM:
synchronous  Design of magnetic circuit, Open circuit characteristic, Determination of
full load field MMF, Design of field winding, Determination of direct
Machine and quadrature axis synchronous reactance, Short circuit
characteristics.
DESIGN OF TURBO ALTERNATORS:
 Main dimensions, Length of air gap, Stator & Rotor design. Design
considerations for low speed alternators and vertically operated alternator.
Computer programs and flow charts based on above topics.

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 144


 Numerical Problem on direct & quadrature reactance
Recap  Design of turbo alternator: Main Dimensions

 Numerical problems on design of main dimensions of


turbo alternator
SLO
 Numerical problem on stator design

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 145


1. A 2000KVA, 32 pole, 50 Hz, 2200 V, star connected
salient pole alternator has the following design data:
Numerical Stator Bore = 1.8 m, Core Length = 0.5 m , Turns per
Problem on phase = 250 , winding factor = 0.955 , air gap length = 10
mm , air gap contraction factor = 1.15 , ratio of pole arc to
direct and pole pitch = 0.65 , ratio of amplitude of fundamental 0f
quadrature maximum gap density to gap flux density = 1.07 , per unit
leakage reactance = 0.15 Ω.
synchronous Determine the direct and quadrature axis reactance.
reactance

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 146


Given that: Solution:
Q = 2000 KVA
7.54𝑓𝑇𝑝ℎ 2 .𝐾𝑤 2 .𝐷𝐿
P = 32 𝑥𝑚 = × 10−6
𝑝2 .𝑙𝑔 .𝐾𝑔
f = 50 Hz
V = 2200 V 7.54×50×2502 ×0.9552 ×1.8×0.5
𝑥𝑚 = × 10−6
322 ×0.01×1.15
D = 1.8 m
L = 0.5 m 𝑥𝑚 = 1.642 Ω
𝑇𝑝ℎ = 250 Voltage per phase ,
𝐾𝑤 = 0.955 2200
𝑙𝑔 = 0.01 𝑚 𝐸𝑝ℎ = = 1270.17 𝑉
3
𝐾𝑔 = 1.15 𝑄×1000
Current per phase, 𝐼𝑝ℎ =
𝜓 = 0.65 3.𝐸𝑝ℎ
𝐴1 = 1.07 2000×1000
𝐼𝑝ℎ = = 524.864 𝐴
𝑋𝑙 = 0.15 Ω 3×1270.17

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 147


Given that: 𝐼𝑝ℎ .𝑥𝑚
Q = 2000 KVA Per unit magnetising reactance, 𝑋𝑚 =
𝐸𝑝ℎ
P = 32 1.642×524.864
f = 50 Hz 𝑋𝑚 = = 0.6785 Ω
1270.17
V = 2200 V
Angle embrace by pole arc, 𝛼 = 𝜓. 𝜋
D = 1.8 m
L = 0.5 m 𝛼 = 0.65 × 𝜋 = 2.042 𝑟𝑎𝑑 = 117°
𝑇𝑝ℎ = 250 𝐴𝑑1 = 𝑓𝑙𝑢𝑥 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑓𝑜𝑟 𝑑𝑖𝑟𝑒𝑐𝑡 𝑎𝑥𝑖𝑠
𝐾𝑤 = 0.955 𝐴𝑑1 = 𝜌𝑑 × 𝐴1
𝑙𝑔 = 0.01 𝑚 𝛼+sin 𝛼
𝜌𝑑 =
𝐾𝑔 = 1.15 4.sin 𝛼Τ2
𝜓 = 0.65 𝜌𝑑 =
2.042+sin 117
= 0.8599
𝐴1 = 1.07 4.sin 117Τ2
𝑋𝑙 = 0.15 Ω
28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 148
Given that: 𝐴𝑑1 = 𝜌𝑑 × 𝐴1
Q = 2000 KVA 𝐴𝑑1 = 0.8599 × 1.07 = 0.92
P = 32
f = 50 Hz Per unit direct axis armature reaction reactance,
V = 2200 V 𝑋𝑎𝑑 = 𝐴𝑑1 . 𝑋𝑚
D = 1.8 m
𝑋𝑎𝑑 = 0.92 × 0.6785 = 0.624 Ω
L = 0.5 m
𝑇𝑝ℎ = 250 Per Unit quadrature axis armature reactance, 𝑋𝑎𝑞
𝐾𝑤 = 0.955 𝑋𝑎𝑞 = 𝐴𝑞1 × 𝑋𝑚
𝑙𝑔 = 0.01 𝑚
4𝜓+1 sin 𝜓𝜋
𝐾𝑔 = 1.15 𝐴𝑞1 =
5

𝜋
𝜓 = 0.65 4×0.65+1 sin 0.65×𝜋
𝐴1 = .097 𝐴𝑞1 = − = 0.72 − 0.26 = 0.46
5 𝜋
𝑋𝑙 = 0.15 Ω

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 149


Given that:
Q = 2000 KVA
𝑋𝑎𝑞 = 𝐴𝑞1 × 𝑋𝑚
P = 32
f = 50 Hz 𝑋𝑎𝑞 = 0.46 × 0.6785 = 0.312 Ω
V = 2200 V
D = 1.8 m Per Unit Direct axis synchronous reactance,
L = 0.5 m 𝑋𝑑 = 𝑋𝑙 + 𝑋𝑎𝑑
𝑇𝑝ℎ = 250 𝑋𝑑 = 0.15 +0.624 = 0.8037 Ω
𝐾𝑤 = 0.955
𝑙𝑔 = 0.01 𝑚 Per Unit Quadrature axis synchronous reactance,
𝐾𝑔 = 1.15 𝑋𝑞 = 𝑋𝑙 + 𝑋𝑎𝑞
𝜓 = 0.65 𝑋𝑞 = 0.15 + 0.312 = 0. 462 Ω
𝐴1 = 1.07
𝑋𝑙 = 0.15 Ω

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 150


 The value of specific loading for conventionally cooled
generators are:
𝐵𝑎𝑣 = 0.54 𝑡𝑜 0.65 𝑊𝑏
ൗ𝑚2
𝑎𝑐 = 50000 𝑡𝑜 75000 𝐴/𝑚
 The value of specific loading for water cooled
Design of generators are:
turbo-alternator 𝐵𝑎𝑣 = 0.54 𝑡𝑜 0.62 𝑊𝑏
ൗ𝑚2
𝑎𝑐 = 180,000 𝑡𝑜 200,000 𝐴/𝑚
 In design of turbo-alternator, the value of stator bore is
limited by the peripheral speed.
 The maximum allowable peripheral speed is 175 m/sec.

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 151


 Estimate the diameter, core length, size and number of
conductor, number of slots for stator of a 25 MVA, 13.8
kV, 50 Hz, 2 pole star connected turbo alternator, 60°
Design of phase spread of distribution factor as 0.955 with
following data:
turbo- 𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2
alternator: 𝑎𝑐 = 54000 𝐴/𝑚
Calculation of Current density, 𝛿 = 5 𝐴Τ𝑚𝑚2
Main Peripheral speed ,𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐
Dimensions The winding should be arranged to eliminate 5𝑡ℎ
harmonics.

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 152


Solution:
2.𝑓
Given that: Synchronous speed, 𝑛𝑠 =
𝑝
Q = 25000 KVA 2×50
𝑛𝑠 = = 50 𝑟𝑝𝑠
V = 13800 V 2
f = 50 Hz 𝑣𝑎 = 𝜋. 𝐷. 𝑛𝑠
p=2 120
𝐷= = 0.7639 𝑚
𝜋×50
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2
To eliminate the 5th harmonics, the coils should be
𝑎𝑐 = 54000 𝐴/𝑚 chorded by an angle:
𝛿 = 5 𝐴Τ𝑚𝑚2 180
𝛼= = 36°
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 5
𝐾𝑑 = 0.955 𝐾𝑝 = cos 𝛼 Τ2
𝐾𝑝 = cos 18 = 0.951

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 153


The winding factor, 𝐾𝑤 = 𝐾𝑑 × 𝐾𝑝
Given that: 𝐾𝑤 = 0.951 × 0.955 = 0.908
Q = 25000 KVA
V = 13800 V Output coefficient, 𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 × 10−3
f = 50 Hz 𝐶0 = 11 × 0.55 × 54000 × 0.908 × 10−3
p=2 𝐶0 = 294.6436 3
KVA
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 𝑚 −𝑟𝑝s
𝑄
𝑎𝑐 = 54000 𝐴/𝑚 2
𝐷 .𝐿 =
𝐶0 .𝑛𝑠
𝛿 = 5 𝐴Τ𝑚2 25000
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 𝐷2 . 𝐿 = = 1.6855 𝑚3
294.6436×50
𝐾𝑑 = 0.955 𝐿=
1.6855
= 2.888 𝑚
0.76392

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 154


Flux per pole, 𝜙 = 𝐵𝑎𝑣 . 𝜏. 𝐿
Given that: 𝜋.𝐷 𝜋×0.7639
Q = 25000 KVA Pole pitch, 𝜏 = = = 1.199 𝑚
𝑝 2
V = 13800 V
Flux per pole, 𝜙 = 0.55 × 1.199 × 2.888 = 1.904 𝑤𝑏
f = 50 Hz 13800
p=2 Voltage per phase, 𝐸𝑝ℎ = = 7967.433 𝑉
3
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 Turns per phase,
𝑎𝑐 = 54000 𝐴/𝑚 7967.433
𝛿 = 5 𝐴Τ𝑚𝑚2 𝑇𝑝ℎ = = 20.75 ≅ 20
4.44×50×1.904×0.908
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 Total Number of Stator conductors, 𝑍 = 6. 𝑇𝑝ℎ
𝐾𝑑 = 0.955 𝑍 = 6 × 20 = 120

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 155


𝑄×1000
Given that: Current Per phase, 𝐼𝑝ℎ =
3𝐸𝑝ℎ
Q = 25000 KVA
25000×1000
V = 13800 V 𝐼𝑝ℎ = = 1045.92 𝐴
3×7967.433
f = 50 Hz As the current is more than 400 A, so taking number of
p=2 parallel path = 2
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 1045.92
Current in each conductor, 𝐼𝑧 = = 522.96 𝐴
𝑎𝑐 = 54000 𝐴/𝑚 2
𝛿 = 5 𝐴Τ𝑚𝑚2 Area of each Conductor, 𝑎𝑧 =
𝐼𝑧
𝛿
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 522.96
𝐾𝑑 = 0.955 𝑎𝑧 = = 104.592 𝑚𝑚2
5

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 156


Given that: To avoid 5th harmonics, the number of slots must be
multiple of 5.The winding should be chorded by 1/5th of
Q = 25000 KVA pole pitch with double layer winding.
V = 13800 V
f = 50 Hz Using 5 slots per pole per phase, 𝑞 = 5
p=2 Total number of slots,
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 𝑆 =𝑞×𝑚×𝑝
𝑎𝑐 = 54000 𝐴/𝑚 𝑆 = 5 × 3 × 2 = 30
𝛿 = 5 𝐴Τ𝑚𝑚2
Conductors per slots, 𝑍𝑠
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐
120
𝐾𝑑 = 0.955 𝑍𝑠 =
30
=4

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 157


 A 3000 r.p.m, 50 Hz, 3 phase turbo alternator has a core
length of 1.8 m. The average gap density is 0.65 𝑊𝑏ൗ𝑚2
Design of and the ampere conductor per metre is 60000 A/m. The
turbo- peripheral speed of rotor is 120 m/sec and the length of
air-gap is 15 mm. find the KVA output of the machine
alternator: when the coils are:
Calculation of i. Full pitch
Main ii. Chorded by 1/3 pole pitch
Dimensions The winding can be taken as infinitely distributed with a
phase spread as 60°.

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 158


Given that: Solution:
𝑁 3000
N= 3000 r.p.m. Synchronous speed, 𝑛𝑠 = = = 50 𝑟. 𝑝. 𝑠.
60 60
f = 50 Hz 𝑣𝑎
L = 1.8 m 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , 𝐷𝑟 =
𝜋.𝑛𝑠
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2 𝐷𝑟 =
𝑣𝑎
=
120
= 0.7639 𝑚
ac = 60000 A/m 𝜋.𝑛𝑠 𝜋×50

𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐 Stator Bore , 𝐷 = 𝐷𝑟 + 2. 𝑙𝑔


𝑙𝑔 = 0.015 𝑚 𝐷 = 0.7639 + 2 × 0.015 = 0.7939 𝑚
𝛼 = 60° With infinite distribution and phase spread of 60° , the
Q=? distribution factor, 𝐾𝑑 = 0.955

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 159


Case I:
Given that: For full pitch coil winding, 𝐾𝑝 = 1
N= 3000 r.p.m. So winding factor, 𝐾𝑤 = 0.955 × 1 = 0.955
f = 50 Hz Now ,
L = 1.8 m 𝑄 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 𝐷2 . 𝐿. 𝑛𝑠 × 10−3
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2 𝑄 = 11 × 0.65 × 60000 × 0.955 × 0.79372 × 1.8 × 50 × 10−3
ac = 60000 A/m 𝑄 = 23228.22 𝐾𝑉𝐴
𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐 Case II:
𝑙𝑔 = 0.015 𝑚 180
Angle of chording, 𝛼 = = 60°
𝛼 = 60° 3
Q=? Pitch Factor, 𝐾𝑝 = cos(𝛼Τ2)
𝐾𝑝 = cos 30 = 0.866

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 160


Given that:
N= 3000 r.p.m.
f = 50 Hz
L = 1.8 m Winding Factor, 𝐾𝑤 = 𝐾𝑝 × 𝐾𝑑
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2
𝐾𝑤 = 0.955 × 0.866 = 0.827
ac = 60000 A/m
𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐
𝑙𝑔 = 0.015 𝑚
𝛼 = 60°
Q=?

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 161


 Solved numerical problems on determination of direct
and quadrature axis synchronous reactance.
Summary  Introduced design of turbo alternator in terms of main
dimension
 Discussed stator design of turbo alternator

 Will discuss rotor design of turbo alternator


Next Session
 Will introduce all types of losses

28-10-2023 Design of Turbo Alternator: Calculation of main dimensions 162


DESIGN OF SYNCHRONOUS MACHINE:
Output equation and design of main dimensions, Short Circuit Ratio (SCR)
and its significance, Length of air gap and shape of pole face.
ARMATURE DESIGN:
 Armature winding (Single layer and double layer), Number of armature
slots, Slot dimensions, Length of mean turn, Calculation of armature
UNIT III resistance and reactance.
Design of DESIGN OF FIELD SYSTEM:
synchronous  Design of magnetic circuit, Open circuit characteristic, Determination of
full load field MMF, Design of field winding, Determination of direct
Machine and quadrature axis synchronous reactance, Short circuit
characteristics.
DESIGN OF TURBO ALTERNATORS:
 Main dimensions, Length of air gap, Stator & Rotor design. Design
considerations for low speed alternators and vertically operated alternator.
Computer programs and flow charts based on above topics.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 163


 Design of turbo alternator: Main Dimensions
Recap  Numerical problems on design of main dimensions of
turbo alternator

 Numerical problem on stator design


SLO
 Length of airgap calculation

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 164


1. Estimate the diameter, core length, size and number of
conductor, number of slots for stator of a 25 MVA,
13.8 kV, 50 Hz, 2 pole star connected turbo alternator,
Design of 60° phase spread of distribution factor as 0.955 with
following data:
turbo- 𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2
alternator: 𝑎𝑐 = 54000 𝐴/𝑚
Calculation of Current density, 𝛿 = 5 𝐴Τ𝑚𝑚2
Main Peripheral speed ,𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐
Dimensions The winding should be arranged to eliminate 5𝑡ℎ
harmonics.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 165


Solution:
2.𝑓
Given that: Synchronous speed, 𝑛𝑠 =
𝑝
Q = 25000 KVA 2×50
𝑛𝑠 = = 50 𝑟𝑝𝑠
V = 13800 V 2
f = 50 Hz 𝑣𝑎 = 𝜋. 𝐷. 𝑛𝑠
p=2 120
𝐷= = 0.7639 𝑚
𝜋×50
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2
To eliminate the 5th harmonics, the coils should be
𝑎𝑐 = 54000 𝐴/𝑚 chorded by an angle:
𝛿 = 5 𝐴Τ𝑚𝑚2 180
𝛼= = 36°
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 5
𝐾𝑑 = 0.955 𝐾𝑝 = cos 𝛼 Τ2
𝐾𝑝 = cos 18 = 0.951

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 166


The winding factor, 𝐾𝑤 = 𝐾𝑑 × 𝐾𝑝
Given that: 𝐾𝑤 = 0.951 × 0.955 = 0.908
Q = 25000 KVA
V = 13800 V Output coefficient, 𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 × 10−3
f = 50 Hz 𝐶0 = 11 × 0.55 × 54000 × 0.908 × 10−3
p=2 𝐶0 = 294.6436 3
KVA
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 𝑚 −𝑟𝑝s
𝑄
𝑎𝑐 = 54000 𝐴/𝑚 2
𝐷 .𝐿 =
𝐶0 .𝑛𝑠
𝛿 = 5 𝐴Τ𝑚2 25000
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 𝐷2 . 𝐿 = = 1.6855 𝑚3
294.6436×50
𝐾𝑑 = 0.955 𝐿=
1.6855
= 2.888 𝑚
0.76392

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 167


Flux per pole, 𝜙 = 𝐵𝑎𝑣 . 𝜏. 𝐿
Given that: 𝜋.𝐷 𝜋×0.7639
Q = 25000 KVA Pole pitch, 𝜏 = = = 1.199 𝑚
𝑝 2
V = 13800 V
Flux per pole, 𝜙 = 0.55 × 1.199 × 2.888 = 1.904 𝑤𝑏
f = 50 Hz 13800
p=2 Voltage per phase, 𝐸𝑝ℎ = = 7967.433 𝑉
3
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 Turns per phase,
𝑎𝑐 = 54000 𝐴/𝑚 7967.433
𝛿 = 5 𝐴Τ𝑚𝑚2 𝑇𝑝ℎ = = 20.75 ≅ 20
4.44×50×1.904×0.908
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 Total Number of Stator conductors, 𝑍 = 6. 𝑇𝑝ℎ
𝐾𝑑 = 0.955 𝑍 = 6 × 20 = 120

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 168


𝑄×1000
Given that: Current Per phase, 𝐼𝑝ℎ =
3𝐸𝑝ℎ
Q = 25000 KVA
25000×1000
V = 13800 V 𝐼𝑝ℎ = = 1045.92 𝐴
3×7967.433
f = 50 Hz As the current is more than 400 A, so taking number of
p=2 parallel path = 2
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 1045.92
Current in each conductor, 𝐼𝑧 = = 522.96 𝐴
𝑎𝑐 = 54000 𝐴/𝑚 2
𝛿 = 5 𝐴Τ𝑚𝑚2 Area of each Conductor, 𝑎𝑧 =
𝐼𝑧
𝛿
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 522.96
𝐾𝑑 = 0.955 𝑎𝑧 = = 104.592 𝑚𝑚2
5

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 169


Given that: To avoid 5th harmonics, the number of slots must be
multiple of 5.The winding should be chorded by 1/5th of
Q = 25000 KVA pole pitch with double layer winding.
V = 13800 V
f = 50 Hz Using 5 slots per pole per phase, 𝑞 = 5
p=2 Total number of slots,
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 𝑆 =𝑞×𝑚×𝑝
𝑎𝑐 = 54000 𝐴/𝑚 𝑆 = 5 × 3 × 2 = 30
𝛿 = 5 𝐴Τ𝑚𝑚2
Conductors per slots, 𝑍𝑠
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐
120
𝐾𝑑 = 0.955 𝑍𝑠 =
30
=4

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 170


2. A 3000 r.p.m, 50 Hz, 3 phase turbo alternator has a
core length of 1.8 m. The average gap density is
Design of 0.65 𝑊𝑏ൗ𝑚2 and the ampere conductor per metre is
turbo- 60000 A/m. The peripheral speed of rotor is 120 m/sec
and the length of air-gap is 15 mm. find the KVA
alternator: output of the machine when the coils are:
Calculation of i. Full pitch
Main ii. Chorded by 1/3 pole pitch
Dimensions The winding can be taken as infinitely distributed with a
phase spread as 60°.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 171


Given that: Solution:
𝑁 3000
N= 3000 r.p.m. Synchronous speed, 𝑛𝑠 = = = 50 𝑟. 𝑝. 𝑠.
60 60
f = 50 Hz 𝑣𝑎
L = 1.8 m 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , 𝐷𝑟 =
𝜋.𝑛𝑠
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2 𝐷𝑟 =
𝑣𝑎
=
120
= 0.7639 𝑚
ac = 60000 A/m 𝜋.𝑛𝑠 𝜋×50

𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐 Stator Bore , 𝐷 = 𝐷𝑟 + 2. 𝑙𝑔


𝑙𝑔 = 0.015 𝑚 𝐷 = 0.7639 + 2 × 0.015 = 0.7939 𝑚
𝛼 = 60° With infinite distribution and phase spread of 60° , the
Q=? distribution factor, 𝐾𝑑 = 0.955

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 172


Case I:
Given that: For full pitch coil winding, 𝐾𝑝 = 1
N= 3000 r.p.m. So winding factor, 𝐾𝑤 = 0.955 × 1 = 0.955
f = 50 Hz Now ,
L = 1.8 m 𝑄 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 𝐷2 . 𝐿. 𝑛𝑠 × 10−3
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2 𝑄 = 11 × 0.65 × 60000 × 0.955 × 0.79372 × 1.8 × 50 × 10−3
ac = 60000 A/m 𝑄 = 23228.22 𝐾𝑉𝐴
𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐 Case II:
𝑙𝑔 = 0.015 𝑚 180
Angle of chording, 𝛼 = = 60°
𝛼 = 60° 3
Q=? Pitch Factor, 𝐾𝑝 = cos(𝛼Τ2)
𝐾𝑝 = cos 30 = 0.866

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 173


Given that:
N= 3000 r.p.m. Winding Factor, 𝐾𝑤 = 𝐾𝑝 × 𝐾𝑑
f = 50 Hz 𝐾𝑤 = 0.955 × 0.866 = 0.827
L = 1.8 m 𝑄 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 𝐷2 . 𝐿. 𝑛𝑠 × 10−3
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2
𝑄 = 11 × 0.65 × 60000 × 0.827 × 0.79372 × 1.8 × 50 × 10−3
ac = 60000 A/m
𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐 𝑄 = 20114.9 𝐾𝑊
𝑙𝑔 = 0.015 𝑚
𝛼 = 60°
Q=?

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 174


3. A 600 MVA, 22000 V, 50 Hz, 2 Pole, 3 phase star
connected direct water cooled generator has a stator
bore of 1.3 m and stator core length of 6 m. If the
stator winding has 2 conductors per slot and there are
Design of two circuit per phase. Calculate:
Turbo- a) Number of stator slots
alternator b) Flux per pole
c) Average flux density in air-gap
The specific electric loading is 200000 ampere conductors
per meter. Assume a winding factor of 0.92.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 175


Given that: Solution:
Q = 600 MVA Synchronous speed, 𝑛𝑠 =
2.𝑓
𝑝
V=22000 V 2×50
f = 50 Hz 𝑛𝑠 = = 50 r.p.s.
2
22000
p=2 𝐸𝑝ℎ =
3
= 12701.7 𝑉
D = 1.3 m 𝑄∗1000
𝐼𝑝ℎ =
L = 6.0 m 3.𝐸𝑝ℎ

a=2 600×103 ×1000


𝐼𝑝ℎ = = 15745.92 𝐴
3×12701.1
ac = 200000A/m 𝐼𝑝ℎ
𝐾𝑤 = 0.92 Current in each conductor , 𝐼𝑧 =
2
𝑍𝑠 = 2 𝐼𝑧 = 7872.96 𝐴

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 176


𝑎𝑐×𝜋𝐷
Given that: Total Number of conductors, 𝑍 =
𝐼𝑧
Q = 600 MVA 𝑍=
200000×𝜋×1.3
= 103.74 ≅ 104
7872.96
V=22000 V 𝑍
f = 50 Hz Turns per phase, 𝑇𝑝ℎ =
6
p=2 104
𝑇𝑝ℎ = = 17.33 ≅ 18
6
D = 1.3 m Updated number of conductors, 𝑍 = 18 × 6 = 108
L = 6.0 m 𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠
a=2 Number of Slots , 𝑆 =
𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠 𝑝𝑒𝑟 𝑠𝑙𝑜𝑡
ac = 200000A/m 𝑆=
108
= 54
2
𝐾𝑤 = 0.92 The number of conductors are 108 and number of slots as
𝑍𝑠 = 2 54 is suitable for double layer winding.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 177


Given that: Flux per pole, 𝜙 =
𝐸𝑝ℎ ×𝑎
4.44×𝑓×𝑇𝑝ℎ ×𝐾𝑤
Q = 600 MVA
12701.7×2
V=22000 V 𝜙=
4.44×50×18×0.92
= 6.91 𝑤𝑏
f = 50 Hz Pole pitch, 𝜏 =
𝜋.𝐷
=
𝜋×1.3
= 2.042 𝑚
𝑝 2
p=2 𝜙×𝑝
D = 1.3 m Average flux density, 𝐵𝑎𝑣 =
𝜋𝐷𝐿
L = 6.0 m 𝐵𝑎𝑣 =
6.91×2
= 0.5639 𝑤𝑏Τ𝑚2
𝜋×1.3×6
a=2
ac = 200000A/m
𝐾𝑤 = 0.92
𝑍𝑠 = 2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 178


Length of air-gap can be calculated using following steps:
1. Approximate value of armature ampere conductors
per pole = 𝑎𝑐. 𝜏
𝑎𝑐.𝜏
2. Armature MMF per pole, 𝐴𝑇𝑎 =
2
3. No-load field MMF, 𝐴𝑇𝑓0 = 𝑆𝐶𝑅 × 𝐴𝑇𝑎
Length of air-
The value of SCR for modern turbo alternator is
gap considered as 0.5 to 0.7.
4. MMF require for air-gap, 𝐴𝑇𝑔 = 0.8 × 𝐴𝑇𝑓0
𝐴𝑇𝑔 = 0.8 × 𝑆𝐶𝑅 × 𝑎𝑐. 𝜏 (1)
𝐴𝑇𝑔 = 800000. 𝑙𝑔 𝐵𝑔 𝐾𝑔 (2)

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 179


0.8×𝑆𝐶𝑅×𝑎𝑐.𝜏
5. Length of airgap, 𝑙𝑔 =
800000×𝐵𝑔 𝐾𝑔

6. Always Consider the value of maximum gap density


Length of air- as 1.5 times of average gap density.
gap 𝐵𝑔 = 1.5𝐵𝑎𝑣
Where 𝐵𝑎𝑣 = specific magnetic loading

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 180


 Find main dimensions, length of airgap, number of stator
conductors, stator slots and slot dimensions of 30000 KVA, 11
KV, 50 HZ, 2 pole and 3 phase star connected air cooled turbo-
alternator. The load power factor is 0.8 lagging. Design data
should be considered as given:
Numerical Specific electric loading, ac = 54000 A/m
Problem on Specific magnetic loading 𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
length of air- Winding factor, 𝐾𝑤 = 0.955
gap Peripheral speed, 𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
Gap contraction factor, 𝐾𝑔 = 1.1
Flux density of core , 𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 181


2.𝑓
Given data: Synchronous speed, 𝑛𝑠 =
𝑝
Q= 30000 KVA 2×50
V= 11000 V 𝑛𝑠 = = 50 r.p.s.
2
f= 50 Hz Output coefficient, 𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 × 10−3
p=2
m=3 𝐶0 = 11 × 0.55 × 54000 × 0.955 × 10−3 = 312
cos 𝜙 = 0.8 Product, 𝐷2 𝐿 =
𝑄
ac = 54000 A/m 𝐶0 ×𝑛𝑠
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝐷2 . 𝐿 =
30000
= 1.923 𝑚3
312×50
𝐾𝑤 = 0.955 𝑣𝑎
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , 𝐷 =
𝜋.𝑛𝑠
SCR = 0.55 𝑣𝑎 130
𝐾𝑔 = 1.1 𝐷= = = 0.8276 𝑚
𝜋.𝑛𝑠 𝜋×50
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 182


Given data:
Q= 30000 KVA
V= 11000 V
f= 50 Hz 1.923
Length of core, 𝐿 = = 2.8 𝑚
p=2 0.82762
𝑎𝑐.𝜏
m=3 Armature MMF per pole, 𝐴𝑇𝑎 =
2
cos 𝜙 = 0.8 𝜋.𝐷 𝜋×0.8276
ac = 54000 A/m 𝜏= = = 1.3 𝑚
𝑝 2
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 54000×1.3
𝐴𝑇𝑎 = = 35100 𝐴
𝐾𝑤 = 0.955 2
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 183


Summary  Solved numerical problem on stator design
 Solved numerical problem on length of air-gap

 Will discuss rotor design of turbo alternator


Next Session  Will introduce all types of losses

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 184


 Design of turbo alternator: Main Dimensions
Recap  Numerical problems on design of main dimensions of
turbo alternator

 Numerical problem on stator design


SLO
 Length of airgap calculation

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 186


1. Estimate the diameter, core length, size and number of
conductor, number of slots for stator of a 25 MVA,
13.8 kV, 50 Hz, 2 pole star connected turbo alternator,
Design of 60° phase spread of distribution factor as 0.955 with
following data:
turbo- 𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2
alternator: 𝑎𝑐 = 54000 𝐴/𝑚
Calculation of Current density, 𝛿 = 5 𝐴Τ𝑚𝑚2
Main Peripheral speed ,𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐
Dimensions The winding should be arranged to eliminate 5𝑡ℎ
harmonics.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 187


Solution:
2.𝑓
Given that: Synchronous speed, 𝑛𝑠 =
𝑝
Q = 25000 KVA 2×50
𝑛𝑠 = = 50 𝑟𝑝𝑠
V = 13800 V 2
f = 50 Hz 𝑣𝑎 = 𝜋. 𝐷. 𝑛𝑠
p=2 120
𝐷= = 0.7639 𝑚
𝜋×50
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2
To eliminate the 5th harmonics, the coils should be
𝑎𝑐 = 54000 𝐴/𝑚 chorded by an angle:
𝛿 = 5 𝐴Τ𝑚𝑚2 180
𝛼= = 36°
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 5
𝐾𝑑 = 0.955 𝐾𝑝 = cos 𝛼 Τ2
𝐾𝑝 = cos 18 = 0.951

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 188


The winding factor, 𝐾𝑤 = 𝐾𝑑 × 𝐾𝑝
Given that: 𝐾𝑤 = 0.951 × 0.955 = 0.908
Q = 25000 KVA
V = 13800 V Output coefficient, 𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 × 10−3
f = 50 Hz 𝐶0 = 11 × 0.55 × 54000 × 0.908 × 10−3
p=2 𝐶0 = 294.6436 3
KVA
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 𝑚 −𝑟𝑝s
𝑄
𝑎𝑐 = 54000 𝐴/𝑚 2
𝐷 .𝐿 =
𝐶0 .𝑛𝑠
𝛿 = 5 𝐴Τ𝑚2 25000
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 𝐷2 . 𝐿 = = 1.6855 𝑚3
294.6436×50
𝐾𝑑 = 0.955 𝐿=
1.6855
= 2.888 𝑚
0.76392

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 189


Flux per pole, 𝜙 = 𝐵𝑎𝑣 . 𝜏. 𝐿
Given that: 𝜋.𝐷 𝜋×0.7639
Q = 25000 KVA Pole pitch, 𝜏 = = = 1.199 𝑚
𝑝 2
V = 13800 V
Flux per pole, 𝜙 = 0.55 × 1.199 × 2.888 = 1.904 𝑤𝑏
f = 50 Hz 13800
p=2 Voltage per phase, 𝐸𝑝ℎ = = 7967.433 𝑉
3
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 Turns per phase,
𝑎𝑐 = 54000 𝐴/𝑚 7967.433
𝛿 = 5 𝐴Τ𝑚𝑚2 𝑇𝑝ℎ = = 20.75 ≅ 20
4.44×50×1.904×0.908
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 Total Number of Stator conductors, 𝑍 = 6. 𝑇𝑝ℎ
𝐾𝑑 = 0.955 𝑍 = 6 × 20 = 120

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 190


𝑄×1000
Given that: Current Per phase, 𝐼𝑝ℎ =
3𝐸𝑝ℎ
Q = 25000 KVA
25000×1000
V = 13800 V 𝐼𝑝ℎ = = 1045.92 𝐴
3×7967.433
f = 50 Hz As the current is more than 400 A, so taking number of
p=2 parallel path = 2
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 1045.92
Current in each conductor, 𝐼𝑧 = = 522.96 𝐴
𝑎𝑐 = 54000 𝐴/𝑚 2
𝛿 = 5 𝐴Τ𝑚𝑚2 Area of each Conductor, 𝑎𝑧 =
𝐼𝑧
𝛿
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐 522.96
𝐾𝑑 = 0.955 𝑎𝑧 = = 104.592 𝑚𝑚2
5

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 191


Given that: To avoid 5th harmonics, the number of slots must be
multiple of 5.The winding should be chorded by 1/5th of
Q = 25000 KVA pole pitch with double layer winding.
V = 13800 V
f = 50 Hz Using 5 slots per pole per phase, 𝑞 = 5
p=2 Total number of slots,
𝐵𝑎𝑣 = 0.55 𝑊𝑏ൗ𝑚2 𝑆 =𝑞×𝑚×𝑝
𝑎𝑐 = 54000 𝐴/𝑚 𝑆 = 5 × 3 × 2 = 30
𝛿 = 5 𝐴Τ𝑚𝑚2
Conductors per slots, 𝑍𝑠
𝑣𝑎 = 120 𝑚/𝑠𝑒𝑐
120
𝐾𝑑 = 0.955 𝑍𝑠 =
30
=4

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 192


2. A 3000 r.p.m, 50 Hz, 3 phase turbo alternator has a
core length of 1.8 m. The average gap density is
Design of 0.65 𝑊𝑏ൗ𝑚2 and the ampere conductor per metre is
turbo- 60000 A/m. The peripheral speed of rotor is 120 m/sec
and the length of air-gap is 15 mm. find the KVA
alternator: output of the machine when the coils are:
Calculation of i. Full pitch
Main ii. Chorded by 1/3 pole pitch
Dimensions The winding can be taken as infinitely distributed with a
phase spread as 60°.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 193


Given that: Solution:
𝑁 3000
N= 3000 r.p.m. Synchronous speed, 𝑛𝑠 = = = 50 𝑟. 𝑝. 𝑠.
60 60
f = 50 Hz 𝑣𝑎
L = 1.8 m 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , 𝐷𝑟 =
𝜋.𝑛𝑠
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2 𝐷𝑟 =
𝑣𝑎
=
120
= 0.7639 𝑚
ac = 60000 A/m 𝜋.𝑛𝑠 𝜋×50

𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐 Stator Bore , 𝐷 = 𝐷𝑟 + 2. 𝑙𝑔


𝑙𝑔 = 0.015 𝑚 𝐷 = 0.7639 + 2 × 0.015 = 0.7939 𝑚
𝛼 = 60° With infinite distribution and phase spread of 60° , the
Q=? distribution factor, 𝐾𝑑 = 0.955

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 194


Case I:
Given that: For full pitch coil winding, 𝐾𝑝 = 1
N= 3000 r.p.m. So winding factor, 𝐾𝑤 = 0.955 × 1 = 0.955
f = 50 Hz Now ,
L = 1.8 m 𝑄 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 𝐷2 . 𝐿. 𝑛𝑠 × 10−3
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2 𝑄 = 11 × 0.65 × 60000 × 0.955 × 0.79372 × 1.8 × 50 × 10−3
ac = 60000 A/m 𝑄 = 23228.22 𝐾𝑉𝐴
𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐 Case II:
𝑙𝑔 = 0.015 𝑚 180
Angle of chording, 𝛼 = = 60°
𝛼 = 60° 3
Q=? Pitch Factor, 𝐾𝑝 = cos(𝛼Τ2)
𝐾𝑝 = cos 30 = 0.866

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 195


Given that:
N= 3000 r.p.m. Winding Factor, 𝐾𝑤 = 𝐾𝑝 × 𝐾𝑑
f = 50 Hz 𝐾𝑤 = 0.955 × 0.866 = 0.827
L = 1.8 m 𝑄 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 . 𝐷2 . 𝐿. 𝑛𝑠 × 10−3
𝐵𝑎𝑣 = 0.65 𝑤𝑏ൗ𝑚2
𝑄 = 11 × 0.65 × 60000 × 0.827 × 0.79372 × 1.8 × 50 × 10−3
ac = 60000 A/m
𝑣𝑎 = 120 𝑚Τ𝑠𝑒𝑐 𝑄 = 20114.9 𝐾𝑊
𝑙𝑔 = 0.015 𝑚
𝛼 = 60°
Q=?

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 196


3. A 600 MVA, 22000 V, 50 Hz, 2 Pole, 3 phase star
connected direct water cooled generator has a stator
bore of 1.3 m and stator core length of 6 m. If the
stator winding has 2 conductors per slot and there are
Design of two circuit per phase. Calculate:
Turbo- a) Number of stator slots
alternator b) Flux per pole
c) Average flux density in air-gap
The specific electric loading is 200000 ampere conductors
per meter. Assume a winding factor of 0.92.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 197


Given that: Solution:
Q = 600 MVA Synchronous speed, 𝑛𝑠 =
2.𝑓
𝑝
V=22000 V 2×50
f = 50 Hz 𝑛𝑠 = = 50 r.p.s.
2
22000
p=2 𝐸𝑝ℎ =
3
= 12701.7 𝑉
D = 1.3 m 𝑄∗1000
𝐼𝑝ℎ =
L = 6.0 m 3.𝐸𝑝ℎ

a=2 600×103 ×1000


𝐼𝑝ℎ = = 15745.92 𝐴
3×12701.1
ac = 200000A/m 𝐼𝑝ℎ
𝐾𝑤 = 0.92 Current in each conductor , 𝐼𝑧 =
2
𝑍𝑠 = 2 𝐼𝑧 = 7872.96 𝐴

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 198


𝑎𝑐×𝜋𝐷
Given that: Total Number of conductors, 𝑍 =
𝐼𝑧
Q = 600 MVA 𝑍=
200000×𝜋×1.3
= 103.74 ≅ 104
7872.96
V=22000 V 𝑍
f = 50 Hz Turns per phase, 𝑇𝑝ℎ =
6
p=2 104
𝑇𝑝ℎ = = 17.33 ≅ 18
6
D = 1.3 m Updated number of conductors, 𝑍 = 18 × 6 = 108
L = 6.0 m 𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠
a=2 Number of Slots , 𝑆 =
𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠 𝑝𝑒𝑟 𝑠𝑙𝑜𝑡
ac = 200000A/m 𝑆=
108
= 54
2
𝐾𝑤 = 0.92 The number of conductors are 108 and number of slots as
𝑍𝑠 = 2 54 is suitable for double layer winding.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 199


Given that: Flux per pole, 𝜙 =
𝐸𝑝ℎ ×𝑎
4.44×𝑓×𝑇𝑝ℎ ×𝐾𝑤
Q = 600 MVA
12701.7×2
V=22000 V 𝜙=
4.44×50×18×0.92
= 6.91 𝑤𝑏
f = 50 Hz Pole pitch, 𝜏 =
𝜋.𝐷
=
𝜋×1.3
= 2.042 𝑚
𝑝 2
p=2 𝜙×𝑝
D = 1.3 m Average flux density, 𝐵𝑎𝑣 =
𝜋𝐷𝐿
L = 6.0 m 𝐵𝑎𝑣 =
6.91×2
= 0.5639 𝑤𝑏Τ𝑚2
𝜋×1.3×6
a=2
ac = 200000A/m
𝐾𝑤 = 0.92
𝑍𝑠 = 2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 200


Length of air-gap can be calculated using following steps:
1. Approximate value of armature ampere conductors
per pole = 𝑎𝑐. 𝜏
𝑎𝑐.𝜏
2. Armature MMF per pole, 𝐴𝑇𝑎 =
2
3. No-load field MMF, 𝐴𝑇𝑓0 = 𝑆𝐶𝑅 × 𝐴𝑇𝑎
Length of air-
The value of SCR for modern turbo alternator is
gap considered as 0.5 to 0.7.
4. MMF require for air-gap, 𝐴𝑇𝑔 = 0.8 × 𝐴𝑇𝑓0
𝐴𝑇𝑔 = 0.8 × 𝑆𝐶𝑅 × 𝑎𝑐. 𝜏 (1)
𝐴𝑇𝑔 = 800000. 𝑙𝑔 𝐵𝑔 𝐾𝑔 (2)

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 201


0.8×𝑆𝐶𝑅×𝑎𝑐.𝜏
5. Length of airgap, 𝑙𝑔 =
800000×𝐵𝑔 𝐾𝑔

6. Always Consider the value of maximum gap density


Length of air- as 1.5 times of average gap density.
gap 𝐵𝑔 = 1.5𝐵𝑎𝑣
Where 𝐵𝑎𝑣 = specific magnetic loading

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 202


 Core Losses
 They can be reduced by decreasing the thickness of the
laminations and using low-loss magnetic materials such
as iron-nickel alloys, oriented silicon steel, or
Types of losses amorphous magnetic materials.
in  Stray-Load Loss
Synchronous  It is caused by the induced losses from the leakage
fluxes of the armature and variations of the flux
Generator distribution in the air gap. This loss includes the eddy
current losses that occur in large armature conductors.
This component of the stray-load loss is minimized by
laminating the armature conductors using bundled
conductors, strip conductors, etc. A typical value of this
loss is around 1 percent of the power output.
28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 203
 Armature Conductor Loss
 The armature conductor loss is defined as the sum of ohmic
(or dc) loss and the effective (or ac) loss in the armature
conductors.
 The effective loss is caused by the nonuniform flux
Types of losses distribution over the cross section of the conductor. This is
known as the skin effect.
in  It depends on the cross section of the conductor and the
frequency of the armature current.
Synchronous  The armature conductors are normally laminated or
Generator segmented to reduce this loss.
 Excitation Loss
 The excitation loss includes the loss of the field conductor
and the automatic voltage regulator which controls the
voltage at the terminals of the machine.
 The heat losses from the field conductor are normally
included in the armature heat losses.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 204


 Find main dimensions, length of airgap, number of stator
conductors, stator slots and slot dimensions of 30000 KVA, 11
KV, 50 HZ, 2 pole and 3 phase star connected air cooled turbo-
alternator. The load power factor is 0.8 lagging. Design data
should be considered as given :
Numerical Specific electric loading, ac = 54000 A/m
Problem on Specific magnetic loading 𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
length of air- Winding factor, 𝐾𝑤 = 0.955
gap Peripheral speed, 𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
Gap contraction factor, 𝐾𝑔 = 1.1
Flux density of core , 𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 205


Given data: I: Main Dimensions
Q= 30000 KVA 2.𝑓
V= 11000 V Synchronous speed, 𝑛𝑠 =
𝑝
f= 50 Hz 𝑛𝑠 =
2×50
= 50 r.p.s.
p=2 2
m=3 Output coefficient, 𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 × 10−3
cos 𝜙 = 0.8 𝐶0 = 11 × 0.55 × 54000 × 0.955 × 10−3 = 312
ac = 54000 A/m Product, 𝐷2 𝐿 =
𝑄
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝐶0 ×𝑛𝑠
30000
𝐾𝑤 = 0.955 𝐷2 . 𝐿 = = 1.923 𝑚3
312×50
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 𝑣𝑎
SCR = 0.55 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , 𝐷 =
𝜋.𝑛𝑠
𝐾𝑔 = 1.1 𝐷=
𝑣𝑎
=
130
= 0.8276 𝑚
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 𝜋.𝑛𝑠 𝜋×50

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 206


Given data:
1.923
Q= 30000 KVA Length of core, 𝐿 = = 2.8 𝑚
0.82762
V= 11000 V
f= 50 Hz II: Length of Air-gap
𝑎𝑐.𝜏
p=2 Armature MMF per pole, 𝐴𝑇𝑎 =
2
m=3 𝜋.𝐷 𝜋×0.8276
cos 𝜙 = 0.8 𝜏= = = 1.3 𝑚
𝑝 2
ac = 54000 A/m 54000×1.3
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝐴𝑇𝑎 = = 35100 𝐴
2
𝐾𝑤 = 0.955 No load field MMF, 𝐴𝑇𝑓0 = 𝑆𝐶𝑅 × 𝐴𝑇𝑎
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55 𝐴𝑇𝑓0 = 0.55 × 35100 = 19305 𝐴
𝐾𝑔 = 1.1 MMF for air-gap, 𝐴𝑇𝑔 = 0.8 × 19305 = 15444 𝐴
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 207


Given data: Maximum flux density in the gap, 𝐵𝑔 = 1.5 𝐵𝑎𝑣
Q= 30000 KVA
V= 11000 V 𝐵𝑔 = 1.5 × 0.55 = 0.825 𝑊𝑏Τ𝑚2
f= 50 Hz 𝐴𝑇𝑔
Length of air-gap, 𝑙𝑔 =
p=2 800000×𝐵𝑔 𝐾𝑔
m=3 15444
𝑙𝑔 = = 0.2127 𝑚
cos 𝜙 = 0.8 800000×0.825×1.1
ac = 54000 A/m 𝑙𝑔 = 21.27 𝑚𝑚 ≅ 20 𝑚𝑚
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
Diameter of rotor, 𝐷𝑟 = 𝐷 − 2. 𝑙𝑔
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 𝐷𝑟 = 0.8276 − 2 × 0.02 = 0.7876 𝑚
SCR = 0.55 Peripheral speed of rotor,
𝐾𝑔 = 1.1
𝑣𝑎 = 𝜋 × 0.7876 × 50 = 123.71 𝑚/𝑠𝑒𝑐
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 208


Given data:
Q= 30000 KVA III: Stator winding:
V= 11000 V
f= 50 Hz Flux per pole, 𝜙 = 𝐵𝑎𝑣 . 𝜏. 𝐿
p=2 𝜙 = 0.55 × 1.3 × 2.8 = 2.002 𝑤𝑏
m=3 11000
𝐸𝑝ℎ = = 6350.853 𝑉
cos 𝜙 = 0.8 3
ac = 54000 A/m Turns per phase,
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 6350.853
𝐾𝑤 = 0.955 𝑇𝑝ℎ = = 14.96 ≅ 15
4.44×50×2.002×0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Total armature conductors, 𝑍 = 6. 𝑇𝑝ℎ
SCR = 0.55
𝐾𝑔 = 1.1 𝑍 = 6 × 15 = 90
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 209


Given data:
Q= 30000 KVA
V= 11000 V
IV: Number of slots
f= 50 Hz
p=2 Assuming slots per pole per phase , 𝑞 = 5
m=3 Number of slots, 𝑆𝑠 = 5 × 3 × 2 = 30
cos 𝜙 = 0.8 90
ac = 54000 A/m Conductor per slot, 𝑍𝑠 = =3
30
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝜋𝐷
Stator slot pitch, 𝑦𝑠 =
𝐾𝑤 = 0.955 𝑆
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 𝜋×0.8276
𝑦𝑠 = = 0.086 𝑚 ≅ 86 𝑚𝑚
SCR = 0.55 30

𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 210


Given data: V: Magnetic Circuit design:
Q= 30000 KVA
V= 11000 V Combined radial and axial ventilation is used. As we
know the duct is 10 mm used for ventilation and the space
f= 50 Hz between two ducts in radial and axial must be between 50
p=2 mm to 100 mm.
m=3 2800
cos 𝜙 = 0.8 So number of ducts ,𝑛𝑑 = = 28
100
ac = 54000 A/m
As we have to provide cooling through out surface of
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 generator so we will arrange 28 ducts around overall
𝐾𝑤 = 0.955 armature periphery.
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55 We have to arrange 28 ducts in different layers which
called as packets.
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 211


Given data:  The arrangement is shown as below:
Q= 30000 KVA No. of Packets Gross length used Length in meter
V= 11000 V 6 packets of 100 mm 6 × 100 × 10−3 0.6 m
f= 50 Hz 4 packets of 90 mm 4 × 90 × 10−3 0.36 m
p=2 3 packets of 70 mm 3 × 80 × 10−3 0.21 m
m=3
2 packets of 60 mm 2 × 70 × 10−3 0.12 m
cos 𝜙 = 0.8
3 packets of 70 mm 3 × 80 × 10−3 0.21 m
ac = 54000 A/m
4 packets of 90 mm 4 × 90 × 10−3 0.36 m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
6 packets of 100 mm 6 × 100 × 10−3 0.6 m
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐  28 packets of total Length = 2.46 m
SCR = 0.55
 Now 28 ducts for axial cooling each 10mm wide
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2  Length of axial ducts = 0.28 m
 Total Core length = 2.46+0.28 = 2.74 m
28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 212
Given data: VI: Stator Core:
Q= 30000 KVA Net iron length, 𝐿𝑖 = 0.9 × 2.52 = 2.268 𝑚
V= 11000 V 𝜙 2
f= 50 Hz Flux in core, 𝜙𝑐 = = = 1 𝑤𝑏Τ𝑚2
2 1
p=2 𝐹𝑙𝑢𝑥 𝑖𝑛 𝑐𝑜𝑟𝑒
Area of stator core, 𝐴𝑐𝑠 =
m=3 𝐹𝑙𝑢𝑥 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝑐𝑜𝑟𝑒
cos 𝜙 = 0.8 𝐴𝑐𝑠 = = 1𝑚2
1
ac = 54000 A/m 1
1
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 Depth of core, 𝑑𝑐𝑠 = = 0.44 𝑚
2.268
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Axial ventilation ducts are provided in the core. So, 20%
area will be lost.
SCR = 0.55
𝐾𝑔 = 1.1 Depth of core, 𝑑𝑐𝑠 = 1.2 × 0.44 = 0.528 𝑚
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 213


Given data:
Q= 30000 KVA VII: Design of Ventilating Holes:
V= 11000 V Assuming 96% efficiency at the rated output,
f= 50 Hz
p=2 Rated output = 30000 × 0.8 = 24000 𝐾𝑊
m=3 Total losses = 24000 × 0.04 = 960 𝑊
cos 𝜙 = 0.8 Taking temperature rise of 25℃ in stator and air inlet
ac = 54000 A/m temperature at 20 ℃,
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝐾𝑤 = 0.955 Air required for cooling of the machine,
𝑄 𝜃𝑖 +273 760
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 = 0.78 × . ×
𝜃 273 ℎ
SCR = 0.55 960 20+270 760
𝐾𝑔 = 1.1 = 0.78 × . × = 32.14 𝑚3 /𝑠𝑒𝑐
25 273 760
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 214


Given data: Due to axial and radial cooling system, air will enter from both
Q= 30000 KVA ends.
V= 11000 V Air entering in the machine from each end
f= 50 Hz 32.14 𝑚3
= = 16.07
p=2 2 𝑠𝑒𝑐
m=3 Assume that 70% of the air enters the stator axial ventilating
cos 𝜙 = 0.8 ducts and the rest 30 % enters the machine via airgap and rotor
axial ducts.
ac = 54000 A/m
Air entering in stator axial ducts
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝐾𝑤 = 0.955 = 0.7 × 16.07 = 11.24 𝑚3 Τ𝑠𝑒𝑐
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Assume air velocity as 25 m/sec.
SCR = 0.55 Area of axial holes required in stator
𝐾𝑔 = 1.1 11.24
= = 0.45 𝑚2
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 25

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 215


Given data: VIII: Slot Dimensions
Q= 30000 KVA
V= 11000 V In order to reduce short circuit forces, leakage reactance
must be high so providing deep slots.
f= 50 Hz
p=2 To obtain a high leakage reactance, a space, which is left
m=3 as reactance space, taken as 30 mm.
cos 𝜙 = 0.8 At this point, the diameter of stator
ac = 54000 A/m
= 0.83 + 2 × 30 × 10−3 = 0.89 𝑚
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝜋𝐷 𝜋×0.89
𝐾𝑤 = 0.955 Slot pitch, 𝑦𝑠 = = = 0.0932 𝑚 = 93.2 𝑚𝑚
𝑆𝑠 30
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
Assuming flux density in stator slots = 1.8 𝑤𝑏
SCR = 0.55 ൗ𝑚2
𝐾𝑔 = 1.1 Minimum width of tooth =
𝜙
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 (𝑆𝑠 Τ𝑝)×𝐿𝑖 ×1.8

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 216


Given data: Minimum width of tooth =
Q= 30000 KVA 2
V= 11000 V = 0.03266 𝑚 = 32.66 𝑚𝑚
(30Τ2)×2.268×1.8
f= 50 Hz Maximum allowable slot width
p=2
m=3 = 93.2 − 32.66 = 60.54 𝑚𝑚
cos 𝜙 = 0.8 𝑄×1000
Armature current per phase, 𝐼𝑝ℎ =
3.𝐸𝑝ℎ
ac = 54000 A/m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝐼𝑝ℎ =
30000×1000
= 1574.59 𝐴
3 ×6350.85
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Taking a current density of 3 𝐴Τ𝑚2 .
SCR = 0.55 1574.59
Area of stator conductor, 𝑎𝑠 = = 524.86 𝑚2
𝐾𝑔 = 1.1 3

𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 Using a conductor of 30 mm width.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 217


Given data: 524.86
Height of conductor = = 17.49 ≅ 17.5 𝑚𝑚
Q= 30000 KVA 30
V= 11000 V If a solid conductor of 30𝑚𝑚 × 17.5 𝑚𝑚 is used. The
f= 50 Hz eddy current losses will be increased and to avoid the
p=2 excessive amount of heat we will divide this conductor in
sub sections.
m=3
cos 𝜙 = 0.8 So using, 6 sub-sections . Area of each sub-section ,
540
ac = 54000 A/m = 90 𝑚𝑚2
6
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 90
𝐾𝑤 = 0.955 So actual height of conductor = = 3 𝑚𝑚
30
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Using insulation between each sub division as 0.25 mm.
SCR = 0.55 Conductor insulation = 0.75 mm
𝐾𝑔 = 1.1
Coil Insulation = 4 mm
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 218


Given data:
Q= 30000 KVA
V= 11000 V
f= 50 Hz
p=2
m=3
cos 𝜙 = 0.8 Slot Width:
ac = 54000 A/m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 219


Summary  Solved numerical problem on stator design
 Solved numerical problem on length of air-gap

 Will discuss rotor design of turbo alternator


Next Session  Will introduce all types of losses

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 220


Recap  Numerical problem on stator design
 Length of airgap calculation
 Design of Magnetic circuit

SLO
 Design of rotor of turbo alternator
 Numerical Problem on design of rotor

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 221


Length of air-gap can be calculated using following steps:
1. Approximate value of armature ampere conductors
per pole = 𝑎𝑐. 𝜏
𝑎𝑐.𝜏
2. Armature MMF per pole, 𝐴𝑇𝑎 =
2
3. No-load field MMF, 𝐴𝑇𝑓0 = 𝑆𝐶𝑅 × 𝐴𝑇𝑎
Length of air-
The value of SCR for modern turbo alternator is
gap considered as 0.5 to 0.7.
4. MMF require for air-gap, 𝐴𝑇𝑔 = 0.8 × 𝐴𝑇𝑓0
𝐴𝑇𝑔 = 0.8 × 𝑆𝐶𝑅 × 𝑎𝑐. 𝜏 (1)
𝐴𝑇𝑔 = 800000. 𝑙𝑔 𝐵𝑔 𝐾𝑔 (2)

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 222


0.8×𝑆𝐶𝑅×𝑎𝑐.𝜏
5. Length of airgap, 𝑙𝑔 =
800000×𝐵𝑔 𝐾𝑔

6. Always Consider the value of maximum gap density


Length of air- as 1.5 times of average gap density.
gap 𝐵𝑔 = 1.5𝐵𝑎𝑣
Where 𝐵𝑎𝑣 = specific magnetic loading

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 223


 Core Losses
 They can be reduced by decreasing the thickness of the
laminations and using low-loss magnetic materials such
as iron-nickel alloys, oriented silicon steel, or
Types of losses amorphous magnetic materials.
in  Stray-Load Loss
Synchronous  It is caused by the induced losses from the leakage
fluxes of the armature and variations of the flux
Generator distribution in the air gap. This loss includes the eddy
current losses that occur in large armature conductors.
This component of the stray-load loss is minimized by
laminating the armature conductors using bundled
conductors, strip conductors, etc. A typical value of this
loss is around 1 percent of the power output.
28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 224
 Armature Conductor Loss
 The armature conductor loss is defined as the sum of ohmic
(or dc) loss and the effective (or ac) loss in the armature
conductors.
 The effective loss is caused by the nonuniform flux
Types of losses distribution over the cross section of the conductor. This is
known as the skin effect.
in  It depends on the cross section of the conductor and the
frequency of the armature current.
Synchronous  The armature conductors are normally laminated or
Generator segmented to reduce this loss.
 Excitation Loss
 The excitation loss includes the loss of the field conductor
and the automatic voltage regulator which controls the
voltage at the terminals of the machine.
 The heat losses from the field conductor are normally
included in the armature heat losses.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 225


 Find main dimensions, length of airgap, number of stator
conductors, stator slots and slot dimensions of 30000 KVA, 11
KV, 50 HZ, 2 pole and 3 phase star connected air cooled turbo-
alternator. The load power factor is 0.8 lagging. Design data
should be considered as given :
Numerical Specific electric loading, ac = 54000 A/m
Problem on Specific magnetic loading 𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
length of air- Winding factor, 𝐾𝑤 = 0.955
gap Peripheral speed, 𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
Gap contraction factor, 𝐾𝑔 = 1.1
Flux density of core , 𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 226


Given data: I: Main Dimensions
Q= 30000 KVA 2.𝑓
V= 11000 V Synchronous speed, 𝑛𝑠 =
𝑝
f= 50 Hz 𝑛𝑠 =
2×50
= 50 r.p.s.
p=2 2
m=3 Output coefficient, 𝐶0 = 11. 𝐵𝑎𝑣 . 𝑎𝑐. 𝐾𝑤 × 10−3
cos 𝜙 = 0.8 𝐶0 = 11 × 0.55 × 54000 × 0.955 × 10−3 = 312
ac = 54000 A/m Product, 𝐷2 𝐿 =
𝑄
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝐶0 ×𝑛𝑠
30000
𝐾𝑤 = 0.955 𝐷2 . 𝐿 = = 1.923 𝑚3
312×50
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 𝑣𝑎
SCR = 0.55 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , 𝐷 =
𝜋.𝑛𝑠
𝐾𝑔 = 1.1 𝐷=
𝑣𝑎
=
130
= 0.8276 𝑚
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 𝜋.𝑛𝑠 𝜋×50

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 227


Given data:
1.923
Q= 30000 KVA Length of core, 𝐿 = = 2.8 𝑚
0.82762
V= 11000 V
f= 50 Hz II: Length of Air-gap
𝑎𝑐.𝜏
p=2 Armature MMF per pole, 𝐴𝑇𝑎 =
2
m=3 𝜋.𝐷 𝜋×0.8276
cos 𝜙 = 0.8 𝜏= = = 1.3 𝑚
𝑝 2
ac = 54000 A/m 54000×1.3
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝐴𝑇𝑎 = = 35100 𝐴
2
𝐾𝑤 = 0.955 No load field MMF, 𝐴𝑇𝑓0 = 𝑆𝐶𝑅 × 𝐴𝑇𝑎
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55 𝐴𝑇𝑓0 = 0.55 × 35100 = 19305 𝐴
𝐾𝑔 = 1.1 MMF for air-gap, 𝐴𝑇𝑔 = 0.8 × 19305 = 15444 𝐴
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 228


Given data: Maximum flux density in the gap, 𝐵𝑔 = 1.5 𝐵𝑎𝑣
Q= 30000 KVA
V= 11000 V 𝐵𝑔 = 1.5 × 0.55 = 0.825 𝑊𝑏Τ𝑚2
f= 50 Hz 𝐴𝑇𝑔
Length of air-gap, 𝑙𝑔 =
p=2 800000×𝐵𝑔 𝐾𝑔
m=3 15444
𝑙𝑔 = = 0.2127 𝑚
cos 𝜙 = 0.8 800000×0.825×1.1
ac = 54000 A/m 𝑙𝑔 = 21.27 𝑚𝑚 ≅ 20 𝑚𝑚
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
Diameter of rotor, 𝐷𝑟 = 𝐷 − 2. 𝑙𝑔
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 𝐷𝑟 = 0.8276 − 2 × 0.02 = 0.7876 𝑚
SCR = 0.55 Peripheral speed of rotor,
𝐾𝑔 = 1.1
𝑣𝑎 = 𝜋 × 0.7876 × 50 = 123.71 𝑚/𝑠𝑒𝑐
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 229


Given data:
Q= 30000 KVA III: Stator winding:
V= 11000 V
f= 50 Hz Flux per pole, 𝜙 = 𝐵𝑎𝑣 . 𝜏. 𝐿
p=2 𝜙 = 0.55 × 1.3 × 2.8 = 2.002 𝑤𝑏
m=3 11000
𝐸𝑝ℎ = = 6350.853 𝑉
cos 𝜙 = 0.8 3
ac = 54000 A/m Turns per phase,
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 6350.853
𝐾𝑤 = 0.955 𝑇𝑝ℎ = = 14.96 ≅ 15
4.44×50×2.002×0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Total armature conductors, 𝑍 = 6. 𝑇𝑝ℎ
SCR = 0.55
𝐾𝑔 = 1.1 𝑍 = 6 × 15 = 90
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 230


Given data:
Q= 30000 KVA
V= 11000 V
IV: Number of slots
f= 50 Hz
p=2 Assuming slots per pole per phase , 𝑞 = 5
m=3 Number of slots, 𝑆𝑠 = 5 × 3 × 2 = 30
cos 𝜙 = 0.8 90
ac = 54000 A/m Conductor per slot, 𝑍𝑠 = =3
30
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝜋𝐷
Stator slot pitch, 𝑦𝑠 =
𝐾𝑤 = 0.955 𝑆
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 𝜋×0.8276
𝑦𝑠 = = 0.086 𝑚 ≅ 86 𝑚𝑚
SCR = 0.55 30

𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 231


Given data: V: Magnetic Circuit design:
Q= 30000 KVA
V= 11000 V Combined radial and axial ventilation is used. As we
know the duct is 10 mm used for ventilation and the space
f= 50 Hz between two ducts in radial and axial must be between 50
p=2 mm to 100 mm.
m=3 2800
cos 𝜙 = 0.8 So number of ducts ,𝑛𝑑 = = 28
100
ac = 54000 A/m
As we have to provide cooling through out surface of
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 generator so we will arrange 28 ducts around overall
𝐾𝑤 = 0.955 armature periphery.
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55 We have to arrange 28 ducts in different layers which
called as packets.
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 232


Given data:  The arrangement is shown as below:
Q= 30000 KVA No. of Packets Gross length used Length in meter
V= 11000 V 6 packets of 100 mm 6 × 100 × 10−3 0.6 m
f= 50 Hz 4 packets of 90 mm 4 × 90 × 10−3 0.36 m
p=2 3 packets of 70 mm 3 × 80 × 10−3 0.21 m
m=3
2 packets of 60 mm 2 × 70 × 10−3 0.12 m
cos 𝜙 = 0.8
3 packets of 70 mm 3 × 80 × 10−3 0.21 m
ac = 54000 A/m
4 packets of 90 mm 4 × 90 × 10−3 0.36 m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
6 packets of 100 mm 6 × 100 × 10−3 0.6 m
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐  28 packets of total Length = 2.46 m
SCR = 0.55
 Now 28 ducts for axial cooling each 10mm wide
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2  Length of axial ducts = 0.28 m
 Total Core length = 2.46+0.28 = 2.74 m
28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 233
Given data: VI: Stator Core:
Q= 30000 KVA Net iron length, 𝐿𝑖 = 0.9 × 2.52 = 2.268 𝑚
V= 11000 V 𝜙 2
f= 50 Hz Flux in core, 𝜙𝑐 = = = 1 𝑤𝑏Τ𝑚2
2 1
p=2 𝐹𝑙𝑢𝑥 𝑖𝑛 𝑐𝑜𝑟𝑒
Area of stator core, 𝐴𝑐𝑠 =
m=3 𝐹𝑙𝑢𝑥 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝑐𝑜𝑟𝑒
cos 𝜙 = 0.8 𝐴𝑐𝑠 = = 1𝑚2
1
ac = 54000 A/m 1
1
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 Depth of core, 𝑑𝑐𝑠 = = 0.44 𝑚
2.268
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Axial ventilation ducts are provided in the core. So, 20%
area will be lost.
SCR = 0.55
𝐾𝑔 = 1.1 Depth of core, 𝑑𝑐𝑠 = 1.2 × 0.44 = 0.528 𝑚
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 234


Given data:
Q= 30000 KVA VII: Design of Ventilating Holes:
V= 11000 V Assuming 96% efficiency at the rated output,
f= 50 Hz
p=2 Rated output = 30000 × 0.8 = 24000 𝐾𝑊
m=3 Total losses = 24000 × 0.04 = 960 𝑊
cos 𝜙 = 0.8 Taking temperature rise of 25℃ in stator and air inlet
ac = 54000 A/m temperature at 20 ℃,
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝐾𝑤 = 0.955 Air required for cooling of the machine,
𝑄 𝜃𝑖 +273 760
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 = 0.78 × . ×
𝜃 273 ℎ
SCR = 0.55 960 20+273 760
𝐾𝑔 = 1.1 = 0.78 × . × = 32.14 𝑚3 /𝑠𝑒𝑐
25 273 760
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 235


Given data: Due to axial and radial cooling system, air will enter from both
Q= 30000 KVA ends.
V= 11000 V Air entering in the machine from each end
f= 50 Hz 32.14 𝑚3
= = 16.07
p=2 2 𝑠𝑒𝑐
m=3 Assume that 70% of the air enters the stator axial ventilating
cos 𝜙 = 0.8 ducts and the rest 30 % enters the machine via airgap and rotor
axial ducts.
ac = 54000 A/m
Air entering in stator axial ducts
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝐾𝑤 = 0.955 = 0.7 × 16.07 = 11.24 𝑚3 Τ𝑠𝑒𝑐
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Assume air velocity as 25 m/sec.
SCR = 0.55 Area of axial holes required in stator
𝐾𝑔 = 1.1 11.24
= = 0.45 𝑚2
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 25

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 236


Given data: VIII: Slot Dimensions
Q= 30000 KVA
V= 11000 V In order to reduce short circuit forces, leakage reactance
must be high so providing deep slots.
f= 50 Hz
p=2 To obtain a high leakage reactance, a space, which is left
m=3 as reactance space, taken as 30 mm.
cos 𝜙 = 0.8 At this point, the diameter of stator
ac = 54000 A/m
= 0.83 + 2 × 30 × 10−3 = 0.89 𝑚
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝜋𝐷 𝜋×0.89
𝐾𝑤 = 0.955 Slot pitch, 𝑦𝑠 = = = 0.0932 𝑚 = 93.2 𝑚𝑚
𝑆𝑠 30
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
Assuming flux density in stator slots = 1.8 𝑤𝑏
SCR = 0.55 ൗ𝑚2
𝐾𝑔 = 1.1 Minimum width of tooth =
𝜙
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 (𝑆𝑠 Τ𝑝)×𝐿𝑖 ×1.8

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 237


Given data: Minimum width of tooth =
Q= 30000 KVA 2
V= 11000 V = 0.03266 𝑚 = 32.66 𝑚𝑚
(30Τ2)×2.268×1.8
f= 50 Hz Maximum allowable slot width
p=2
m=3 = 93.2 − 32.66 = 60.54 𝑚𝑚
cos 𝜙 = 0.8 𝑄×1000
Armature current per phase, 𝐼𝑝ℎ =
3.𝐸𝑝ℎ
ac = 54000 A/m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝐼𝑝ℎ =
30000×1000
= 1574.59 𝐴
3 ×6350.85
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Taking a current density of 3 𝐴Τ𝑚2 .
SCR = 0.55 1574.59
Area of stator conductor, 𝑎𝑠 = = 524.86 𝑚2
𝐾𝑔 = 1.1 3

𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 Using a conductor of 30 mm width.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 238


Given data: 524.86
Height of conductor = = 17.49 ≅ 17.5 𝑚𝑚
Q= 30000 KVA 30
V= 11000 V If a solid conductor of 30𝑚𝑚 × 17.5 𝑚𝑚 is used. The
f= 50 Hz eddy current losses will be increased and to avoid the
p=2 excessive amount of heat we will divide this conductor in
sub sections.
m=3
cos 𝜙 = 0.8 So using, 6 sub-sections . Area of each sub-section ,
540
ac = 54000 A/m = 90 𝑚𝑚2
6
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 90
𝐾𝑤 = 0.955 So actual height of conductor = = 3 𝑚𝑚
30
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Using insulation between each sub division as 0.25 mm.
SCR = 0.55 Conductor insulation = 0.75 mm
𝐾𝑔 = 1.1
Coil Insulation = 4 mm
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 239


Given data:
Q= 30000 KVA
V= 11000 V
f= 50 Hz
p=2
m=3
cos 𝜙 = 0.8
ac = 54000 A/m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 240


 Discussed design of stator dimension
Summary  Discussed rotor design of turbo alternator

 Will solve numerical on rotor design


Next Session  Will discuss all specific parameters related to loss

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 241


DESIGN OF SYNCHRONOUS MACHINE:
Output equation and design of main dimensions, Short Circuit Ratio (SCR)
and its significance, Length of air gap and shape of pole face.
ARMATURE DESIGN:
 Armature winding (Single layer and double layer), Number of armature
UNIT III slots, Slot dimensions, Length of mean turn, Calculation of armature
resistance and reactance.
Design of DESIGN OF FIELD SYSTEM:
synchronous  Design of magnetic circuit, Open circuit characteristic, Determination of
Machine full load field MMF, Design of field winding, Determination of direct and
quadrature axis synchronous reactance, Short circuit characteristics.
DESIGN OF TURBO ALTERNATORS:
 Main dimensions, Length of air gap, Stator & Rotor design. Design
considerations for low speed alternators and vertically operated
alternator. Computer programs and flow charts based on above topics.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 242


Recap  Discussed rotor design of turbo alternator
 Discussed design of field winding of turbo alternator

 Will solve numerical problem on design of rotor and


rotor winding
SLO
 Will discuss design consideration of low rpm generators

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 243


 Find main dimensions, length of airgap, number of stator
conductors, stator slots and slot dimensions of 30000 KVA,
11 KV, 50 HZ, 2 pole and 3 phase star connected air
cooled turbo-alternator. The load power factor is 0.8
lagging. Design data should be considered as given :
Specific electric loading, ac = 54000 A/m
Design of Specific magnetic loading 𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
Rotor Winding factor, 𝐾𝑤 = 0.955
Peripheral speed, 𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
Gap contraction factor, 𝐾𝑔 = 1.1
Flux density of core , 𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 244


 From this numerical problem, we have already
calculated following parameters.
Main Dimension , D = 07826 m
Core Length , L = 2.8 m
Design of Length of airgap = 20 mm

Rotor Turns per phase, 𝑇𝑝ℎ = 15


Total numbers of conductors, Z = 90
Conductors per slot, 𝑍𝑠 = 3
Total number of stator slots, 𝑆𝑠 = 30
Flux per pole, 𝜙 = 2.002 𝑤𝑏

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 245


𝐼𝑝ℎ 𝑇𝑝ℎ 𝐾𝑤
Armature MMF per pole, 𝐴𝑇𝑎 = 2.7 ×
Q= 30000 KVA 𝑝
V= 11000 V 30000×1000
𝐼𝑝ℎ = = 1574.59 𝐴
f= 50 Hz 3 ×6350.85
p=2 Turns per phase, 𝑇𝑝ℎ = 15
m=3 2.7×1574.59×15×0.955
𝐴𝑇𝑎 = = 30450.6 𝐴
cos 𝜙 = 0.8 2
ac = 54000 A/m Full load field MMF, 𝐴𝑇𝑓𝑙 = 2. 𝐴𝑇𝑎
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝐴𝑇𝑓𝑙 = 2 × 30450.6 = 60901.2 𝐴
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Taking a current density of 2.5 A/𝑚𝑚2
SCR = 0.55 2.𝐴𝑇𝑓𝑙
Total area of rotor winding conductors per pole =
𝐾𝑔 = 1.1 𝛿𝑓
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 𝑎𝑟 =
2×60901.2
= 48720.96 𝑚𝑚2
2.5

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 246


Q= 30000 KVA Rotor Slots:
V= 11000 V The rotor slot pitch should not have any common factor
f= 50 Hz with stator slot pitch and for a 2 pole design machine, the
p=2 number of wound rotor slots should be a multiple of 4.
m=3
cos 𝜙 = 0.8 Or we can say, the difference between stator and rotor
ac = 54000 A/m slots must be multiplier of number od pole.
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝑆𝑠 − 𝑆𝑟 ≥ 2𝑝
𝐾𝑤 = 0.955
The number of rotor slots can be considered as 23.
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55 Now the number of wound slots must be occupied the
𝐾𝑔 = 1.1 70% of total rotor slots.
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 Hence considerable number of slots, 𝑆𝑟 = 0.7 × 23 = 16

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 247


Rotor design
Comparison

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 248


𝜋.𝐷
Q= 30000 KVA Rotor Slot pitch, 𝑦𝑠𝑟 =
𝑆𝑟
V= 11000 V 𝜋×0.7826
f= 50 Hz 𝑦𝑠𝑟 = = 0.1068 𝑚 = 106.8 𝑚𝑚
23
p=2 𝜋×0.7876
m=3 Rotor pole pitch, 𝜏𝑝𝑟 = = 1.237 𝑚
2
cos 𝜙 = 0.8
Rotor Winding:
ac = 54000 A/m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 Assume exciter voltage = 220V
𝐾𝑤 = 0.955 0.8 𝑡𝑜 0.85 𝑉
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Voltage across each coil, 𝐸𝑓 =
𝑝
SCR = 0.55 Assuming 80% voltage,
𝐾𝑔 = 1.1
0.8×220
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 𝐸𝑓 = = 88 𝑉
2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 249


The length of mean turn, 𝐿𝑚𝑡𝑓 = 2. 𝐿 + 1.8𝜏𝑝𝑟 + 0.25
Q= 30000 KVA
V= 11000 V 𝐿𝑚𝑡𝑓 = 2 × 2.8 + 1.8 × 1.237 + 0.25 = 8.076 𝑚
f= 50 Hz 𝜌.𝐴𝑇𝑓𝑙 .𝐿𝑚𝑡𝑓
p=2 Area of each field conductor, 𝑎𝑓 =
𝐸𝑓
m=3
0.021×60901.2×8.076
cos 𝜙 = 0.8 𝑎𝑓 = = 117.37 𝑚𝑚2
88
ac = 54000 A/m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 Number of field conductors per pole,
𝐾𝑤 = 0.955 𝑡𝑜𝑡𝑎𝑙 𝑓𝑖𝑒𝑙𝑑 𝑤𝑖𝑛𝑑𝑖𝑛𝑔 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 𝑎𝑟𝑒𝑎
𝑍𝑝 =
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑓𝑖𝑒𝑙𝑑 𝑤𝑖𝑛𝑑𝑖𝑛𝑔 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟
SCR = 0.55 48720.96
𝑍𝑝 = = 415.105
𝐾𝑔 = 1.1 117.37
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 16
Wound rotor slots per pole = = 8
2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 250


Conductors per slot per pole,
Q= 30000 KVA 𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠
V= 11000 V 𝑍𝑠𝑝 =
𝑠𝑙𝑜𝑡 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒
f= 50 Hz 415
p=2 𝑍𝑠𝑝 = = 51.88 ≅ 52
8
m=3 Updated total number of conductors,
cos 𝜙 = 0.8
ac = 54000 A/m 𝑍 = 52 × 8 = 416
416
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 Total field turns per pole, 𝑇𝑓 = = 208
2
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Resistance of each field winding conductor,
𝐿𝑚𝑡𝑓
SCR = 0.55 𝑅𝑓 = 𝜌. .𝑇
𝑓
𝐾𝑔 = 1.1 𝑎𝑓
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 𝑅𝑓 =
0.021×208×8.076
= 0.3 Ω
117.37

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 251


𝐸𝑓
Q= 30000 KVA Current in each field winding conductor, 𝐼𝑓 =
𝑅𝑓
V= 11000 V 88
f= 50 Hz 𝐼𝑓 = = 293.33 𝐴
0.3
p=2
m=3 Total MMF developed in field winding,
cos 𝜙 = 0.8 𝐴𝑇𝑓 = 𝐼𝑓 × 𝑇𝑓
ac = 54000 A/m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 𝐴𝑇𝑓 = 293.33 × 208 = 61012.64 A
𝐾𝑤 = 0.955 Slot Dimension:
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55 Choosing a conductor of 40 mm wide and 3 mm deep.
𝐾𝑔 = 1.1 The insulation of slot must be designed to withstand great
mechanical stresses with specific value of thermal
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2
expansion co-efficient.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 252


Q= 30000 KVA  The coil is enclosed in a 0.5 mm steel cell.
V= 11000 V  In order to support the winding at the ventilating ducts, a
f= 50 Hz 2 mm thick spring steel plate is provided at the bottom
p=2 of slot.
m=3
cos 𝜙 = 0.8  The turns are insulated from each other by 0.3 mm mica
ac = 54000 A/m separators.
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2  The coil is wrapped first in a 0.5 mm hard mica cell and
𝐾𝑤 = 0.955 then in a 2 mm flexible mica cell.
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 253


Q= 30000 KVA Slot Width:
V= 11000 V
f= 50 Hz Copper Conductor 1 × 40 40 mm
p=2 Hard mica 2× 0.5 1 mm
m=3 Flexible mica 2× 2 4 mm
cos 𝜙 = 0.8
Steel cell 2× 0.5 1 mm
ac = 54000 A/m
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 Slack 2 mm
𝐾𝑤 = 0.955 Total Slot Width 𝑤𝑠𝑟 48 mm
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐
SCR = 0.55
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 254


Slot Depth:
Q= 30000 KVA
V= 11000 V Copper Conductors 52 ×3 156 mm
f= 50 Hz Wedge 30 mm
p=2 Copper strip under wedge 3 mm
m=3
Hard Mica 3 × 0.5 1.5 mm
cos 𝜙 = 0.8
ac = 54000 A/m Flexible mica 3×2 6 mm
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 Mica Separators 52 × 0.3 15.6 mm
𝐾𝑤 = 0.955 Mica bottom strip 1.5 mm
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Spring steel belt 2 mm
SCR = 0.55 Steel cell 2 × 0.5 1 mm
𝐾𝑔 = 1.1 Slack 2.5 mm
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 Total Slot depth 𝑑𝑠𝑟 219.1 mm

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 255


Rotor Ventilation:
Q= 30000 KVA
V= 11000 V Total Air entering from each end = 16.07 𝑚3 Τ𝑠𝑒𝑐
f= 50 Hz Air entering in stator axial ducts
p=2
m=3 = 0.7 × 16.07 = 11.24 𝑚3 Τ𝑠𝑒𝑐
cos 𝜙 = 0.8 Air entering the gap and axial holes in rotor from each
ac = 54000 A/m end,
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2
𝐾𝑤 = 0.955 = 16.07 − 11.24 = 4.83 𝑚3 Τ𝑠𝑒𝑐
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 Assume air velocity as 25 m/sec.
SCR = 0.55
𝐾𝑔 = 1.1 Area of axial holes required in stator
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2 =
4.83
= 0.198 𝑚2
25

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 256


𝜋
Area to the path of air in the air gap = 𝐷2 − 𝐷𝑟 2
Q= 30000 KVA 4
𝜋
V= 11000 V = 0.82762 − 0.78262
4
f= 50 Hz
p=2 = 0.0569 𝑚2
m=3 Area of ventilating holes required in rotor
cos 𝜙 = 0.8
ac = 54000 A/m = 0.198 – 0.0569
𝐵𝑎𝑣 = 0.55 𝑤𝑏Τ𝑚2 = 0.141 𝑚2
𝐾𝑤 = 0.955
𝑣𝑎 = 130 𝑚/𝑠𝑒𝑐 320 holes of 10 mm diameter area = 0.026 𝑚2
SCR = 0.55 160 holes of 10 mm diameter area = 0.113 𝑚2
𝐾𝑔 = 1.1
Total Area of holes for cooling in rotor = 0.139 𝑚2
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 257


 A 3 phase 16 pole alternator has a star connected
winding with 144 slots and 10 conductors per slot. The
flux per pole is 0.03 Wb sinusoidally distributed and the
speed is 375 r.p.m. Find the frequency and the phase and
line e.m.f. Assume full-pitched coil.
Solution:
Recap As we know that, 𝑁 =
120 .𝑓
, Find frequency.
𝑃
Numerical 𝐾𝑤 = 𝐾𝑝 × 𝐾𝑑
𝑚.𝛽
sin 180°
2
𝐾𝑑 = 𝛽 here 𝛽 =
𝑚.sin 2 𝑠𝑙𝑜𝑡/𝑝𝑜𝑙𝑒

𝐸𝑝ℎ = 4.44𝑓𝜙𝑇𝑝ℎ 𝐾𝑤

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 258


 With the world’s 𝐶𝑂2 levels steadily increasing, and the
limited amount of fossil fuels there is no doubt that we need
to look into renewable sources for energy production.
 Fossil fuels might be easier to use and cheaper to deal but
also increases emission of 𝐶𝑂𝑋 and 𝑁𝑂𝑋 emissions.
Design
 At this condition , as a design engineer we have to design
Considerations some specific generators which can be run at low rpm and
can provide more energy.
of Low speed
 Now we mostly view photovoltaic cells, hydropower, and
Generator wind turbines as the future of renewable energy.
 Both wind and hydroelectric power use the same principle to
produce energy by converting the kinetic energy available in
either running water or the wind and turn it into electric
energy.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 259


 This is done by spinning a turbine that is connected to a
generator. As the turbine spins the generator turns and it
creates useable energy.
 As with solar energy, wind turbines can only be used a
Design portion of the time. That is when the wind is blowing.
Considerations  However, hydroelectric power can be used as long as there
is a current in a stream.
of Low speed  The main problem with these two forms of energy is the
Generator cost is takes to convert the kinetic energy into electric
energy.
 Most low speed generators cost too much money to be
used by much of the world, and thus this form of energy
isn’t readily available.

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 260


Design
Considerations
of Low speed
Generator

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 261


 Discussed design of rotor and rotor winding of non-
salient pole alternator
Summary
 Solved one numerical on rotor and rotor winding design

 Will discuss design considerations for low speed


alternators and vertically operated alternator.
Next Session  Will discuss some flow chart of design process of
electrical machines

28-10-2023 Design of Turbo Alternator: Stator and Rotor Design 262


DESIGN OF SYNCHRONOUS MACHINE:
Output equation and design of main dimensions, Short Circuit Ratio (SCR)
and its significance, Length of air gap and shape of pole face.
ARMATURE DESIGN:
 Armature winding (Single layer and double layer), Number of armature
UNIT III slots, Slot dimensions, Length of mean turn, Calculation of armature
resistance and reactance.
Design of DESIGN OF FIELD SYSTEM:
synchronous  Design of magnetic circuit, Open circuit characteristic, Determination of
Machine full load field MMF, Design of field winding, Determination of direct and
quadrature axis synchronous reactance, Short circuit characteristics.
DESIGN OF TURBO ALTERNATORS:
 Main dimensions, Length of air gap, Stator & Rotor design. Design
considerations for low speed alternators and vertically operated
alternator. Computer programs and flow charts based on above topics.

28-10-2023 Design of Low RPM and Vertically Operated Alternators 263


Recap  Solved numerical problem on design of rotor and rotor
winding
 Discussed design consideration of low rpm generators

 Will discuss some more aspects of design for low speed


alternators and vertically operated generators
SLO  Will discuss about design process and flow chart

28-10-2023 Design of Low RPM and Vertically Operated Alternators 264


 With the world’s 𝐶𝑂2 levels steadily increasing, and the
limited amount of fossil fuels there is no doubt that we need
to look into renewable sources for energy production.
 Fossil fuels might be easier to use and cheaper to deal but
also increases emission of 𝐶𝑂𝑋 and 𝑁𝑂𝑋 emissions.
Design
 At this condition , as a design engineer we have to design
Considerations some specific generators which can be run at low rpm and
can provide more energy.
of Low speed
 Now we mostly view photovoltaic cells, hydropower, and
Generator wind turbines as the future of renewable energy.
 Both wind and hydroelectric power use the same principle to
produce energy by converting the kinetic energy available in
either running water or the wind and turn it into electric
energy.

28-10-2023 Design of Low RPM and Vertically Operated Alternators 265


 This is done by spinning a turbine that is connected to a
generator. As the turbine spins the generator turns and it
creates useable energy.
 As with solar energy, wind turbines can only be used a
Design portion of the time. That is when the wind is blowing.
Considerations  However, hydroelectric power can be used as long as there
is a current in a stream.
of Low speed  The main problem with these two forms of energy is the
Generator cost is takes to convert the kinetic energy into electric
energy.
 Most low speed generators cost too much money to be
used by much of the world, and thus this form of energy
isn’t readily available.

28-10-2023 Design of Low RPM and Vertically Operated Alternators 266


Design
Considerations
of Low speed
Generator

28-10-2023 Design of Low RPM and Vertically Operated Alternators 267


Components
to Low RPM
Alternator

28-10-2023 Design of Low RPM and Vertically Operated Alternators 268


Vertically
operated wind
turbine

28-10-2023 Design of Low RPM and Vertically Operated Alternators 269


VAWTs offer a number of advantages over traditional
horizontal-axis wind turbines:
1. They are omni-directional and do not need to track the
Advantage of wind. This makes them much more reliable due to
their not requiring a complex mechanism and motors
Vertical-axis to yaw the rotor and pitch the blades.
operated wind 2. The gearbox of a VAWT takes much less fatigue than
turbines that of a HAWT. Easy for replacement, less costly and
simpler in design, as the gearbox is easily accessible
at ground level. Motor and gearbox failures generally
increase the operational and maintenance costs of
HAWT wind farms both on and offshore.

28-10-2023 Design of Low RPM and Vertically Operated Alternators 270


3. VAWTs do not need to track the wind to produce energy
as they are omni directional; any claimed inefficiencies
are in fact cancelled out by the VAWT's ability to take
advantage of turbulent and gusty winds. Such winds are
not harvested by HAWTs, and in fact cause accelerated
Advantage of fatigue for HAWTs.
Vertical-axis 4. VAWTs can use a screw pile foundation, allowing a huge
operated wind reduction in the carbon cost of an installation as well as a
reduction in road transport of concrete during installation.
turbines They can be fully recycled at the end of the their life.
5. VAWT wings of the Darrieus type have a constant chord
and so are easier to manufacture than the blades of a
HAWT, which have a much more complex shape and
structure.

28-10-2023 Design of Low RPM and Vertically Operated Alternators 271


6. VAWTs can be grouped more closely in wind farms,
increasing the generated power per unit of land area.
Advantage of 7. VAWTs can be installed on a wind farm below the
Vertical-axis existing HAWTs; this will improve the efficiency
(power output) of the existing farm.
operated wind 8. Research at Caltech has also shown that a carefully
turbines designed wind farm using VAWTs can have an output
power ten times that of a HAWT wind farm of the
same size.

28-10-2023 Design of Low RPM and Vertically Operated Alternators 272


New solar wind hybrid street light system
1. Safe Design: Vertical blade design, Integrated molding, so there
is no risk of a blade flying off, highly increasing the security
coefficient.
2. 360 Degree Wind Available: Vertical wind turbine need not to
Solar-Wind track the wind. So it can adapt to all wind directions and wind
speed. The efficiency of wind using is higher.
Hybrid street
3. Super Quiet: Vertical wind turbine is much quiet than horizontal
lighting wind turbine. Spinning quietly, vertical is suitable for home use.
system 4. Beautiful Design: Vertical wind turbine is designed with
beautiful curve. It is suitable to decorate the road or your roof.
5. Wide Application :Much less limitation to vertical wind turbine
installing. Without the long blades, the vertical wind turbine can
easily adapt to all kinds of environment. Especially suitable for
street lights.

28-10-2023 Design of Low RPM and Vertically Operated Alternators 273


Solar-Wind
Hybrid street
lighting
system

28-10-2023 Design of Low RPM and Vertically Operated Alternators 274


Vertical-axis
wind turbine

28-10-2023 Design of Low RPM and Vertically Operated Alternators 275


Different
design criteria
of shape for
Vertical-axis
wind turbine

28-10-2023 Design of Low RPM and Vertically Operated Alternators 276


Design
Configuration
of Vertical-axis
wind turbine

28-10-2023 Design of Low RPM and Vertically Operated Alternators 277


 In this modern era, the prime endeavour of an electrical
machine lies in designing the machine to become “user-
friendly”.
 Following criteria must be fulfilled for design
specifications:
Design 1. Good performance that fits into the technical
Specification specification
as a design 2. Permissible cost of the machine from the customer
engineer point of view
3. Satisfactory life of the machine in comparison to its
cost
4. Higher operating ranges and suitable for multitasking
5. Easy maintenance and simple in construction

28-10-2023 Design of Low RPM and Vertically Operated Alternators 278


Synthesis
method of
design

28-10-2023 Design of Low RPM and Vertically Operated Alternators 279


Computer
program of
Synchronous
Machine
Design

28-10-2023 Design of Low RPM and Vertically Operated Alternators 280


Summary  Discussed design considerations for low speed
alternators and vertically operated alternator.
 Discussed some flow chart of design process of
electrical machines

Next Session  Will discuss on Finite Element Design process

28-10-2023 Design of Low RPM and Vertically Operated Alternators 281

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