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Design of Synchronous Generator for Pico-Hydropower Plant

Conference Paper · June 2013

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 Design of Synchronous Generator for
Pico-Hydropower Plant
Htet Myat Shein1, Dr. Aung Ze Ya2
1,2
Department of Electrical Power Engineering
Mandalay Technological University

Abstract - Myanmar has natural gifts of hydropower B. Hydraulic Turbines

resources. Consequently, Pico-hydropower is cost effective, Turbines can be crudely classified as high-head,
environmental friendly and manufactured locally. This medium-head, and low-head machines, as shown in Table
system is categorized based on its capability of producing I. Electricity generation usually requires a shaft speed to
the electricity up to 5 kW. This research has studied on the
minimize the speed change between the turbine and the
hydropower generating system and mainly emphasized on
the design of synchronous generator for used in Pico- generator. Since the speed of any given type of turbine
hydropower plant. Fixed-blade, axial flow, the propeller declines with head, low-head sites need turbines that are
turbine is suitable for this hydropower plant. In this paper, inherently faster under a given operating condition.
the design data of 1-phase, 6-pole, 1000 r.p.m, 50 Hz, 5 kVA Turbines are also divided by their principle of operation
synchronous generator is mentioned. The calculated results and can be either impulse or reaction turbines illustrated
are checked based on the design limits and these are in Figures 1 and 2 [1].
regarded as appropriate values.
TABLE I
Keywords – Myanmar, Pico-hydropower, Propeller turbine, TURBINE TYPES BASED ON HEADS
Run-of-river, Synchronous generator
Turbine High-Head Medium-Head Low-Head
Runner (>50m) (10-50m) (<10m)
I. INTRODUCTION Impulse Pelton Crossflow Crossflow
Hydropower has been used for centuries. It is the Turgo Turgo
largest and the oldest renewable energy source of Multi-jet Multi-jet Pelton
electricity generation. It can produce electricity 24 hours Pelton
Reaction Francis Propeller
per day. Where water resources are available, PAT Kaplan
hydropower stations are used to supply electrical energy
to consumer. Hydropower plants have long lives relative
to other forms of energy generation. Pico-hydropower
scheme can produce power for house holding and reduces
depend on fuel resources. Moreover, it is one of the most
effective solutions for the production of electricity and
thus preventing global warning [2].
Pico hydro system may require water storage at non-
invasive level, or may be configured as run-of-river and
not require any damming [1]. Pico-hydropower system is (a) Single-jet Pelton (b) Multi-jet Pelton (c) Turgo (d)Crossflow
a hydropower scheme with maximum power generation Figure 1. Group of impulse turbine
of 5kW that normally found at rural and hilly area.
Common devices which can be powered by Pico- Typical efficiency ranges of turbines are given in
hydropower system are light bulbs, fluorescent lamps, Table II. Turbines are chosen or are sometimes tailor-
radio, televisions, refrigerators and food processors. made according to site conditions. Selecting the right
Hydropower plants provide inexpensive electricity and do turbine is one of the most important parts of designing a
not create air pollution. Water is plentiful, clean and will hydroelectric system, and the skills of an engineer are
never run out [2]. needed in order to choose the effective turbine for a site,
taking into consideration cost, variations in head, flow,
II. OVERVIEW OF PICO-HYDROPOWER PLANT and the amount of sediment in the water and overall
A. Power from Water reliability of the turbine [11].
The amount of available energy depends on the
amount of water flow rate, the gross head and the force of
gravity. Power potential in a particular site can be
calculated by using the following equation [1].
P=QxHxgxη , (1)
where, P - Power output (kW)
Q - Usable flow rate (m3/s)
H - Gross head (m)
g - Gravitational constant (9.8 m/s2) (a) Propeller (b) Francis
η - Efficiency factor (0.5 to 0.7) Figure 2. Group of reaction turbine
 TABLE II By using synchronous generator, there is no affection
EFFICIENCY RANGE OF TURBINES
against grid when parallel running. On the other hand, big
Turbine Type Efficiency Range
Impulse turbines: over-current will rush and voltage drop of grid will occur
Pelton 80-90% if induction generator is applied [5].
Turgo 80-95%
Crossflow 65-85% III. DESIGN THEORY OF SYNCHRONOUS GENERATOR
Reaction turbines:
Francis 80-90% The construction of the 6-pole, synchronous generator
PAT 60-90% is mentioned in Figure 4. It consists of stator, rotor and
Propeller 80-95% losses. Design of stator has main dimension of stator
Kaplan 80-90% frame, stator winding and depth of stator core. Design of
rotor has axial length of pole, width of pole, high of pole,
C. Hydroelectric Generator
air-gap length and outer diameter of the rotor. Losses
Electrical power can be generated in either AC or DC.
consist of total losses of stator winding, total iron losses,
AC has the advantage of allowing the use of common
total field copper losses, exciter losses and friction and
household appliances and tools and is much more
windage losses [5].
economical for transmitting power to consumers. Thus,
AC system is considered in this study [3]. There are
two main types of an AC generator which are used in
hydro-electric scheme. These are Synchronous generator
and Induction generator [2].
Synchronous generators are standard in electrical
power generation and are used in most power plants.
Asynchronous generators are more commonly known as
induction generators. Both of these generators are
available in three-phase or single-phase systems. And,
both machines may have the same stator design but
different rotor design as illustrated in Fig.3. System
capacity, type of load and length of the transmission/
distribution net-work dictate whether a single- or three-
phase generator should be used [11]. Selection of the
generators based on size of scheme is shown in Table III
Figure 4. 6-pole, synchronous generator
[1].
TABLE III A. Main Dimension of Stator Frame
SELECTION OF GENERATOR
Size of Up to 10 kW 10 to 25 kW More than 25 Internal diameter and gross length of the stator frame
Scheme kW are its main dimensions. The output equation is the basic
Type of Induction or Induction or Synchronous, tool to initiate the design of synchronous machine, which
Generator Synchronous, Synchronous, Three-phase relates the output of the machine with the main
and Phase Single or three- Three-phase dimensions of the stator [11].
phase
Output of 1-phase synchronous machine,
Full load load efficiencies of synchronous generators Q = Kʹ D2L ns ,
vary from 75 to 90 percent, depending on the size of the (2)
generator. Efficiency of induction generator is where, D - Internal Diameter of the Stator
approximately 75 percent at full load and decreases to as L - Gross Length of Stator Core
low as 65 percent at part load [11]. If high portions of
loads are likely to be inductive loads, such as motor and Output coefficient of 1-phase synchronous machine,
fluorescent lamps, a synchronous generator is better than Kʹ = (11/3) Bav q Kw x 10-3 , (3)
an induction generator. Induction generators in stand- where, Bav - Specific Magnetic Loading
alone application mode cannot supply the high-surge q - Specific Electric Loading
power required by motor loads during start up [1]. Kw - Winding Factor
For rectangular poles, the ratio of axial length of the
core to pole pitch varies from 0.8 to 3. A suitable ratio
may be assumed for axial length to pole pitch depending
upon the design specifications [5].
L / τP = 0.8 to 3 (4)
Air-gap length,
lg = (0.012 to 0.016) × pole pitch (5)
(a) (b)
B. Design of Stator Winding
Figure 3. Different Rotor Design:
(a) Salient-pole rotor (b) Cylindrical-pole rotors Air-gap flux per pole,
 Φ = Bav τP L (6) dc = Ac/ Lc (27)
Number of stator turns per phase,
Tph = Eph / (4.44 f Φ Kw ) (7) D. Regulation
Slot pitch,
Area of conductor,
τS = πD / number of stator slots (8)
0.8 exciter voltage
Conductors per slot, Vc (28)
ZS = 2 Tph / number of stator slots (9) no of field coil
Cross-sectional area of the conductor, Resistance of field winding,
aS = Full-load current / Current density (10) ρL mtf TF
RF (29)
Number of stator teeth per pole arc, aF
Nt = Pole arc / τS (11) Copper losses in the field winding,
Width of stator tooth at air gap surface, Pcu,loss = If2 Rf (30)
bt = Φ / (Bt Lic Nt) , (12) Total losses in all the coil,
where, Bt - flux density in the stator tooth Ptotal,cu = Pcu,loss pole (31)
Lic - net iron length of stator core Total field copper losses,
Width of the stator slot, Pt,f = Pcu,loss + Ptotal,cu (32)
bs = τS bt (13) Friction and windage losses = 1% of output (33)
Mean length of the stator winding, Efficiency,
Lmt = 2L + 2.5τP + 0.05 kV + 0.15 (14) Pout
Resistance of the stator winding, η 100% (34)
Pin
Rs = Lmt Tph/ aS (15)
Copper losses of stator winding, IV. CALCULATED RESULTS
Pcus = Iph2 Rph (16) The calculated results of the designed generator are
Eddy current losses in the stator winding, mentioned in the following Tables IV to VII.
Peds = ( Kdav 1 ) Pcus (17)
TABLE IV
where, Kdav = average loss factor MAIN DIMENSIONS
Total losses of the stator winding,
Specification Symbol Unit Value
Pts = Pcus + Peds + Pss (18)
where, Pss stay load losses Full load output Q kVA 5
Effective resistance of the stator winding,
Line Voltage V Volts 230
Resistance drop = Iph Rph Kdav (19)
Depth of stator core, Number of phases - - 1
dc = c/ Bc Lic (20)
Frequency f Hz 50
Outer diameter of the stator core,
Do = D + 2hs + 2dc (21) Speed N rpm 1000

C. Design of Rotor Number of poles p - 6

Air gap length,
Output coefficient Kʹ - 25.282
Lg = ATg / 0.796 Bg Kg 106 (22)
Rotor diameter, Internal diameter of stator D m 0.304
Dr = D 2Lg (23)
Gross length of Stator L m 0.127
Width of the pole,
Peripheral speed ν m/s 15.92m/s
bp = Ap / Lp (24)
w ere L axial length of the pole
TABLE V
Heigh of the pole, STATOR DESIGN

TF IF (25)
Specification Symbol Unit Value
hF 4
10 d FSFPF Flux per phase Φ Wb 0.007681

Cross-sectional area of the rotor core, Turns per phase Tph - 144
Ac = 0.5 p / Bc (26)
Depth of rotor core, Conductors per slot ZS - 8
 Number of slots S - 36 Eddy current losses Ped W 1.0055

Specification Symbol Unit Value Specification Symbol Unit Value

Conductor c.s.a as mm2 4.348 Stray load losses Ps W 20.032

Size of conductor - mm 2.36 Iron losses - W 133.49

Rotor copper losses - W 252.384

Width of slot bs m 0.01
Friction and Windage
Width of stator tooth bt m 0.016 - W 40
losses

Teeth per pole arc Nt - 2.803 Total full load losses - W 592.7

Slot Depth hs m 0.00687 Efficiency η % 87

Double
Winding Type - -
layer, Lap V. CONCLUSIONS
Resistance of winding Rph Ω 0.29 Today, rural electrification plays an important role in
rural development. Myanmar has high potential of
Effective resistance - p.u 0.027 hydropower resources. Therefore, pico-hydropower is
recognized as a suitable solution to improving rural
Effective reactance - p.u 0.038 electrification.
This paper mentions the design data of 1-phase, 6-
TABLE VI pole, 1000 r.p.m, 50 Hz, 5 kVA synchronous generator.
ROTOR DESIGN Choice of the suitable values of specific magnetic loading
and specific electric loading are important. Since the
Specification Symbol Unit Value designed generator is salient pole machine, the internal
diameter of the stator is larger than the axial length of the
Rotor diameter Dr m 0.3
stator core. The length of air gap in synchronous
machines is also an important design parameter.
Air-gap length lg m 0.001837
Moreover, the number of stator slots should be
properly chosen, as if affects the cost and the
Axial length of pole lp m 0.117
performance of synchronous machine. The flux density in
the stator tooth at the gap surface should not exceed 1.8
Width of pole bp m 0.0523
Tesla for alternators. Otherwise, the tooth losses will be
High of pole hp m 0.10608
excessive. Furthermore, the choice of the proper value of
the current density is also important. The high current
Short circuit ratio SCR - 0.9 density can be chosen for economical consideration. But,
the resistance of the stator winding increases, resulting in
higher copper loses in the stator winding, thus reducing
Total no load ampere turns AT AT 675.5 the efficiency of the machine. Usual values for the current
density in the stator winding can be assumed varying
Full load field ampere turns ATf AT 1065 from 3 to 5 A/mm2.

Sectional area of field

af mm2 0.802 ACKNOWLEDGEMENT
conductor
First of all, the author wishes to express his deepest
Field current If A 2.807 gratitude to His Excellency Dr. Ko Ko Oo, Minister,
Ministry of Science and Technology, for the opening of
Field turns per coil Tf - 797.77 Master of Engineering course at Mandalay Technological
University. The author wishes to express high gratitude to
Resistance of field winding Rf Ω 5.22 his parents for their encouragements throughout this
study. The author is also deeply gratitude to Dr. Khin Aye
TABLE VII Win and Daw Than Than Win, Visiting Professors,
LOSSES AND EFFICIENCY Department of Electrical Power Engineering, Yangon
Technological University, for sharing their valuable
Specification Symbol Unit Value
experience. The author would like to convey his warmly
gratitude to U Thet Tin, Lecturer, Department of
Exciter loss - W 13.283
Electrical Power Engineering, Mandalay Technological
Copper losses in stator University, for his effective guidance. The author offers
Pcu W 132.55 his special appreciation to Dr. Aung Ze Ya, Associate
winding
Professor, Department of Electrical power Engineering,
 Mandalay Technological University, for his essential
suggestion and continuous supervision for this paper.

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