Handbook of Large Hydro Generators

GLENN MOTTERSHEAD, PEng, is a Principle Engineer at HDR and an IEEE Life Member, has served on numerous IEEE electric machinery committees and standards working groups, with 45 years of experience in all aspects of design, installation, testing, troubleshooting, modernizing and uprating of large synchronous generators. STEFANO BOMBEN, PEng, is a large hydro generator engineer specialist in Ontario, Canada, with over 29 years of experience at a major Ontario utility. His experience includes new generator specifications and installations, rewinds, failure repairs, testing, troubleshooting, and maintenance practices. He has served on numerous IEEE committees and standards working groups relating to large hydro generators and insulation systems. ISIDOR KERSZENBAUM, PHD, is a generator specialist in Irvine, CA, consulting with power plants on operation, maintenance, and troubleshooting of large motors and generators. He is also an IEEE Fellow. GEOFF KLEMPNER, PEng, is a large generator engineer specialist in the power industry and has served on numerous IEEE committees and standards working groups for large generators. He is also an IEEE Fellow and a contributor to CIGRE on large rotating electrical machines.

• Preface xiAbout the Authors xvAcknowledgments xviiChapter 1 Principles of Operation of Synchronous Machines 11.1 Introduction to Basic Notions on Electric Power 11.2 Electrical–Mechanical Equivalence 61.3 Alternating Current (AC) 61.4 Three-Phase Circuits 131.5 Basic Principles of Machine Operation 141.6 The Synchronous Machine 181.7 Synchronous Machine: Basic Operation 23Chapter 2 Generator Design and Construction 352.1 Stator Core 362.2 Stator Frame 502.3 Electromagnetics 542.4 Core-End Heating 622.5 Flux and Armature Reaction 622.6 Stator Core and Frame Forces 642.7 Stator Windings 652.8 Stator Winding Wedges 792.9 Endwinding Support Systems 852.10 Stator Winding Configurations 862.11 Stator Terminal Connections 882.12 Rotor Rim 912.13 Rotor Spider/Drum 1032.14 Rotor Pole Body 1062.15 Rotor Winding and Insulation 1102.16 Amortisseur Winding 1162.17 Slip/Collector Rings and Brush Gear 1192.18 Cooling Air 1222.19 Rotor Fans/Blower 1242.20 Rotor Inertia, Torque, and Torsional Stress 1252.21 Thrust and Guide Bearings 128Chapter 3 Generator Auxiliary Systems 1573.1 Oil Systems 1573.2 Stator Surface Air Cooling System 1613.3 Bearing Cooling Coils and Water Supply 1653.4 Stator Winding Direct Cooling Water System 1673.5 Excitation Systems 1713.6 Excitation System Performance Characteristics 174Chapter 4 Operation and Control 1774.1 Basic Operating Parameters 1774.2 Operating Modes 1884.3 Machine Curves 1904.4 Special Operating Conditions 2004.5 Basic Operation Concepts 2084.6 System Considerations 2254.7 Grid-Induced Torsional Vibrations 2354.8 Excitation and Voltage Regulation 237Chapter 5 Monitoring and Diagnostics 2415.1 Generator Monitoring Philosophies 2425.2 Simple Monitoring with Static High-Level Alarm Limits 2435.3 Dynamic Monitoring with Load Varying Alarm Limits 2445.4 Artificial Intelligence (AI) Diagnostic Systems 2475.5 Monitored Parameters 2505.6 Radio Frequency Monitoring 2735.7 Capacitive Coupling 2745.8 Stator Slot Coupler 2765.9 Rotor 2785.10 Excitation System 286Chapter 6 Generator Protection 2916.1 Basic Protection Philosophy 2916.2 IEEE Device Number 2956.3 Brief Description of Protective Functions 2966.4 Tripping and Alarming Methods 307Chapter 7 Inspection Practices and Methodology 3117.1 Site Preparation 3117.2 Experience and Training 3147.3 Inspection Frequency 3177.4 Generator Accessibility 3187.5 Inspection Tools 3197.6 Inspection Forms 321Chapter 8 Stator Inspection 3378.1 Stator Frame Soleplates 3388.2 Stator Frame: General 3498.3 Stator Core Air Ducts 3548.4 Stator Core Laminations 3568.5 Stator Core Clamping System 3788.6 Stator Coils/Bars 3898.7 Flow Restriction in Water Cooled Stator Windings 3968.8 Stator Wedging System 3988.9 Stator Endwinding 4058.10 Main and Neutral End Leads, Cables, VTs, CTs, and Insulators 411Chapter 9 Rotor Inspection 4179.1 Rotor Spider with Shrunk Laminated Rims 4199.2 Rotor Rim 4309.3 Rotor Poles 4369.4 Rotor Brakes 458Chapter 10 Auxilliaries Inspection 46510.1 Excitation: Field Breaker 46510.2 Excitation: Static Exciter Components 47010.3 Brushless Exciter 47010.4 Static Exciter Transformer 47210.5 Excitation: Rotating Exciters 47310.6 Excitation: Sliprings, Commutator, and Brushes 48110.7 Surface Air Coolers 49910.8 Fire Protection 50210.9 General Items 50410.10 Thrust and Guide Bearing 50710.11 Miscellaneous Auxiliaries 510Chapter 11 Maintenance and Testing 51311.1 Stator Core Mechanical 51311.2 Stator Core Electrical Tests 51811.3 Stator Winding Mechanical Tests 53111.4 Stator Winding Electrical Tests 53411.5 Rotor Mechanical Testing 56811.6 Rotor Electrical Testing 58311.7 Bearings 59011.8 Heat-Run Testing 590Chapter 12 Maintenance Philosophies, Upgrades, and Uprates 59512.1 General Maintenance Philosophies 59512.2 Operational and Maintenance History 59712.3 Maintenance Intervals/Frequency 59812.4 Planned Outages 59912.5 Rehabilitation, Uprating/Upgrading and Life Extension 60112.6 Excitation System Upgrades 61112.7 Workforce 62712.8 Spare Parts 62812.9 Effect of Uprating on Generator Life 62912.10 Required Information, Tests and Inspection Prior to Uprating/Upgrading 63112.11 Maintenance Schedule After Uprating 632Index 633

Hydro generators have been an essential part of the world’s electrical supply for over 100 years and have a power output up to about 1,000 MW. To our knowledge, this is the first book that is specifically focused on how to operate, test, and maintain such machines. This book has a similar format to the well-regarded book Handbook of Large Turbo Generator Operation and Maintenance, written by two of the authors of the hydro generator book (Kerszenbaum and Klempner). This book will be of interest to readers of this magazine because there is a significant focus on the electrical insulation used in hydro generator rotor and stator windings. The main authors are Mottershead and Bomben, who have extensive experience in hydro generator design and operation, respectively. These authors are well known from published papers and their work on IEEE standards working groups. Bomben is currently the chair of the Board of Governors for the IEEE Electrical Insulation Conference.Handbook of Large Hydro Generators: Operation and Maintenance is a practical handbook for engineers and maintenance staff responsible for the upkeep of large salient-pole hydro generators and pumped-storage generators. It first presents the physics and design of large vertical salient-pole generators.The book then offers readers real-world experience, problem description, and solutions, while teaching them about the design, modernization, inspections, maintenance, and operation of salient-pole machines. One of the best aspects are the explanations of what to look for when doing inspections of the rotor and stators. The book also covers generator protection and auxiliary systems inspection. The final two chapters are dedicated to maintenance and testing, and maintenance philosophies, upgrades, and uprates. Perhaps in a future version of this book they will discuss how to repair hydro generators in more detail. The handbook includes over 420 full color photos and 180 illustrations, forms, and tables to complement the topics covered in the chapters. Every hydro generating plant in the world should have a copy of this book.- John Shea, IEEE DEIS Magazine Book Reviews