SYnchronous Machine Design Complete
SYnchronous Machine Design Complete
SYnchronous Machine Design Complete
Chapter: Synchronous
Machine design
3170909
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.
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
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
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
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
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.
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
𝜌 = 0.021Ω − 𝑚𝑚2/𝑚 𝐼𝑓
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2
SLO
Design of rotor of turbo alternator
Numerical Problem on design of rotor
𝐾𝑔 = 1.1
𝐵𝑐 = 1.0 𝑤𝑏Τ𝑚2
𝐸𝑝ℎ = 4.44𝑓𝜙𝑇𝑝ℎ 𝐾𝑤