Toyo Deinki - AC Generators

Generators range from 1 MW to 40 MW.

Salient features : Salient or cylindrical pole. Vacuum Pressure Impregnation suitable for severe environment. Rated Output (kVA): 1000 ~ 50000(4 pole rating) Low voltage regulation - + /- 0.25% Wide choice of Voltage – 415V / 3.3 / 6.6 / 11 / 13.8 kV. Rated speed – 428 ~ 1800 rpm Frequency (Hz): 50 ~ 60. Special frequencies on request. Insulation: Class F Bearing options – Ball / Roller / Sleeve Air Cooled Generators with IP 21/ IP 22 / IP 23 Protection. Totally Enclosed machines with IP54 Protection Applicable Standards – IS, IEC, JEC.

Salient features of TDPS Generator : TDPS’ manufacturing facility was built in 2001 and is equipped with the latest equipment and machinery. A strong team of around 200 staff comprising Engineers, Technicians & staff, supports it. TDPS has established time-tested & proven manufacturing processes in place that require compliance with strict quality standards right from material selection to packing. Design, Manufacturing & Testing of generators are carried out under the guidance and supervision of highly experienced Japanese specialists. Ratings offered :

Rating Chart

(Frame size and Ratings are indicative and may vary depending on application / site conditions.)

Stator :

Stators Frame is of steel plate construction & is designed to withstand vibrations and to ensure effective flow of cooling air.

Stator Core is made of low loss silicon steel sheets with ventilation ducts to enable cooling of core interior.

Stator coils are formed in diamond shape using insulated copper strips of Class F insulation. Formed coils are taped with required layers of resin poor tape & the outer layer covered with Sealant tape. Over hang portion is taped with Semi conducting tape. Individual coils are checked for Surge before insertion.
Stator coils are inserted into the slots of core & arrested with Wedges. Over hangs are secured with glass fiber cord to withstand short circuit forces.

The Stator is subjected to Vacuum Pressure Impregnation (VPI) & cured. Customized VPI process for large generators ensures better heat transfer capability.

Rotor :

Rotor Shaft is made of Forged Steel.

Core is built out of circular Stampings & is rigidly shrunk-fit on the Shaft.

Ventilation ducts are provided for adequate cooling of the Rotor coils.

Rotor is provided with Damper windings on the outer periphery of the core.

Field Winding is with polyamide insulated Copper Strips.

Formed coils are inserted in slots & rigidly arrested by high strength wedges. Winding overhangs are held firmly against centrifugal forces. Larger capacity rotors are held in the overhang by additional high strength stainless steel rings.

For high inertia requirements of diesel engine and high runaway speed conditions for water turbine generators salient pole designs are offered.

Rotor is dynamically balanced to ensure low levels of vibration.

Bearings :

Depending upon the application, output and speed, sleeve, roller or ball bearings are provided.

Exciter : Brushless exciter and rotating rectifier assembly, mounted on the shaft of the main Generator supplies the required excitation to the main generator.

PMG : Permanent magnet generator as pilot exciter is provided as an optional feature.

Excitation System : TDPS Generators are supplied with digital excitation systems. One Auto & one Manual mode is standard. Dual Auto mode (one as hot-standby) can be provided as optional feature. Analogue systems can also be provided on request.

Quality Control :

At TDPS, product quality begins from enquiry / quotation stage and extends through Design, Procurement, Manufacturing & final inspection / testing stages.

• Utmost importance is given to understand the performance requirements, application and operating conditions before submitting offers.
• Product design is checked, vetted & reviewed to ensure compliance with committed performance levels. Stringent quality standards are targeted and achieved by following a systematic Quality Plan for every Generator. The quality plan is detailed & exhaustive and ensures adequate checks at all critical stages right up to the dispatch of the product.

Generators are put through rigorous testing. The TDPS set up is ISO 9001:2000 certified. TDPS generators have been accredited by leading engineering consulting firms.

Testing Process :

All relevant tests, both routine and type, are run on the finished product to ensure performance as per IEC/IS specifications.

Routine tests include

• Resistance measurement of all windings
• Insulation resistance measurement before and after HV
• High voltage test on all windings
• Open circuit and short circuit characteristics
• Phase sequence
• Voltage balance
• Vibration measurement
• Shaft voltage
• Over speed @ 120% rated speed
• Functional check of AVR with Generator

Type tests include :

• Open circuit heat Run
• Short circuit heat run
• Efficiency test by summation of losses method.
• Momentary overload Test
• Sudden short circuit test @ 30% rated voltage
• Noise level test
• Recording of no load wave form, harmonics and THF calculation
• Determination of reactance values by sudden short circuit test
• Vibration test
• Rotor impedance
• GD2 measurement
  

Accreditation and certifications :

TDPS manufacturing facility is ISO 9001-2000 certified by TUV.

TDPS Generators are approved by major engineering consultants like ;

• AVANT GARDE
• M N DASTUR
• TATA CONSULTING ENGINEERS
• FICHTNER
• HOLTEC
• DESEIN
• PDIL
• DCPL
• MITCON.
• JP MUKHERJEE & ASSOCIATES and
• UHDE INDIA
• SPBPC