Design of Synchronous

Machines
Introduction

• Synchronous machines have

• the field circuit excited by external DC source, and
• the armature circuit with three phase balanced winding
excited by an AC source.
• The armature circuit forms the stator of the synchronous
machine, and the field circuit constitutes the rotor of the
machine.
• However, for low power synchronous machines, the
arrangement similar to DC machine can also be used with the
field on the stator side and the armature on the rotor side.
Types of Synchronous Machine
• Synchronous generators are the
synchronous machines driven by steam or
hydraulic turbines, and generate
electricity.
• Synchronous motors are the machines
working on general power supply
networks at 50 Hz, 60 Hz and sometimes
at 25 Hz. They are used in constant speed
drives for compressors, blowers, etc.
• Synchronous compensators are
synchronous motors running at leading
power factor to supply reactive power to a Fig. 1: Classification of synchronous machines
power system network.
Types of Synchronous Generators

• In a synchronous generator, DC excitation given to the

rotor winding produces a magnetic field.

• The rotor is also driven by external prime mover producing

a rotating magnetic field, which induces three-phase
voltage in the stator winding.
Based on types of Prime Mover
Based on the type of the prime mover used, synchronous generators are classified as
follows.
i. Hydro generators:
• driven by hydraulic turbines,
• run at low speeds, less than 1000 rpm,
• Francis turbines, Kaplan turbines and Pelton wheels are the most commonly used
hydraulic turbines.
ii. Turbo generators:
• driven by steam turbines,
• run at very high speeds, above 1500 rpm.
iii. Engine-driven generators:
• driven by various forms of internal combustion engines with speed less than 1500
rpm.
Based on Construction Fig. 2

• The most widely used synchronous machines

have a stationary armature and rotating field
system.
i. Salient pole machine:
• These types of machine have protruding
poles with concentrated windings as
shown in Fig. 2.
• This construction is adopted only for slow
speed machines as it becomes very
difficult to retain the salient poles against
the large centrifugal forces developed.
ii. Non-salient or cylindrical rotor machines: Fig. 3
• Here, the field winding is not
concentrated but distributed in several
slots, which are milled over the rotor
surface as shown in Fig. 3.
• Since the poles are not projecting, this
type of construction can be used for turbo
generators which have high rotating
speeds of 3000 rpm and above.
Constructional Aspects of Synchronous Machines
a. Peripheral speed and centrifugal force

• The peripheral speed of a machine is given by va = πDns m/s , where D is the

diameter of the stator bore (≈ rotor diameter Dr) in m and ns is the speed of the
rotor in rps.
• The volume D2L of a machine has to be increased if the power output has to be
increased.
• However, it has to be noted that D cannot be increased to any extent. There is a
restriction imposed on the diameter ‘D’.
• For a two-pole, 50 Hz machine, with ns = 50 rps, if D = 1.2 m, then va = 188
m/s. This is the maximum possible peripheral speed the corresponding
centrifugal force is maximum which a rotating mass can withstand.
 b. Critical Speed
• The static and dynamic balance of a large rotor must be secured to avoid any dangerous
conditions.
• The rotor is a structure with its mass running in two bearings.
• If the mass centre of rotor of mass ‘m’ is displaced by ‘ε’ from the centre of rotation, then
the centrifugal force exerted on mass will be mω2ε, where ω is the angular velocity.
• This will cause deflection ‘δ’ of the shaft, increasing the centrifugal force to mω2(δ+ε). This
force is opposed by a counter force ‘ kδ ’ in the shaft.
mω2 ε
• For equilibrium, these two forces must be equal, giving δ =
k−mω2
• At some angular velocity, say ‘ωc ’ called critical speed, the denominator becomes zero and
the deflection becomes infinite, which is dangerous for the machine.
• The designer must aim to make the machine operate at a speed away from critical speed as
far as possible.
 c. Runaway Speed

• When a full load is suddenly thrown off, the prime mover tries to race as it
will be receiving full supply of water or diesel or steam. This speed is called
runaway speed.
• In water wheel generators, the speed governors are not quick acting like turbo
generators.
• The runaway speed may be as high as 2.8 times the rated speed causing greater
mechanical stress, and the machine must be designed to bear such great forces.
• The maximum peripheral speed for which a salient pole machine is designed is
generally 140 m/s, while turbo alternators are designed for a maximum
peripheral speed of about 180 m/s.
Construction of Hydro-generators

• These are salient pole machines running at low speeds.

• The construction is mainly based on the type of turbine and water head
available.
• For a given frequency, a large number of poles are demanded at low
speeds and so this type of machine will have larger diameter.
• With diameter as large as 15 m, it is just not possible to transport the
machine as a single unit. Therefore, it is designed to be transported to site
in sections.
• The machine must be designed to withstand the centrifugal stress produced
at twice the normal operating speed as a convention.
• Stator core (Fig. 4): Fig. 4
• The stator core is made of laminations of low
loss silicon steel, usually CRGO.
• The core is supported by dove tail key bars to the
outer cylindrical frame called yoke.
• Winding:
• Three-phase windings are placed inside the slots
of laminated stator.
• Multiturn coils are generally used.
• Rotor (Fig. 5):
• The salient poles are carried on a rotor body. The
type of rotor construction largely depends on the Fig. 5
peripheral speed.
• The rotor poles that are laminated are bolted to
the rotor body for low peripheral speed up to 25
m/s.
• For higher peripheral speeds, dove tailed or T-
headed rotor is used as shown in Fig. 6 and 7,
respectively.
 Fig. 6 Fig. 7

• Rotor winding:
• The rotor coils are formed from rectangular section strips of copper or aluminum.
• Damper windings:
• These are employed to control oscillations hunting in the machine.
• They are copper bars placed through the slots in the pole shoes with end connections attached to the pole
end plates.
• They are also used to provide starting torque in the machine.
Construction of Turbo-generators

• A 50 Hz turbo alternator is essentially a two-pole machine at 3000 rpm.

• The diameter of the rotor is limited to 1.2 m because of the reasons stated
earlier.
• This machine has high efficiency at high speed.
• To increase the rating, the axial length, electric loading, and magnetic
loading of these machines are exceptionally high.
• This will increase the temperature of the machine, and so sophisticated
cooling mechanisms like hydrogen cooling or direct water cooling are to
be adopted.
• Stator core (Fig. 8): Fig. 8
• The stator core is built up of segmental
laminations.
• The slots, ventilation holes and dovetail
key holes are punched together.
• Stator Winding:
• Three-phase, double layer and short
pitched coils are used, and are placed in
the slots on the stator core.
• Rotor (Fig. 9): Fig. 9
• The rotor is a cylindrical structure made
of solid forgings of alloy steel.
• The surface is milled to form the slots.
Normally about two-third of the surface
is slotted and the rest is left unslotted.
• Concentric multi-turn coils are used.
Construction of Synchronous Motors

• The synchronous motors have similar construction as that of

synchronous generators, with the rotor construction mostly with
salient pole.

• These motors are not self-starters; they are started with the help
of damper windings.
Design
Specifications
The following are the specifications of a three-phase synchronous machine, based on
which the machine must be built:
✓kVA capacity
✓Voltage rating
✓Speed
✓Number of poles
✓Number of phases
✓Frequency
✓Regulation
✓Efficiency
✓Temperature rise
✓Cooling method
✓Type of prime-mover, excitation
Output Equation
• The output equation of a synchronous machine is same as that of a three-phase
induction machine is given by
Q = kVA =CoD2L ns
where, Output coefficient, Co = 1.11 π2Kw Bav ac × 10−3 = 11 Kw Bav ac × 10−3
winding factor, Kw = Kd × Kp
𝑡𝑜𝑡𝑎𝑙 𝑓𝑙𝑢𝑥 𝑎𝑟𝑜𝑢𝑛𝑑 𝑡ℎ𝑒 𝑎𝑖𝑟 𝑔𝑎𝑝 𝑝𝜑𝑚
specific magnetic loading, 𝐵𝑎𝑣 = =
𝑎𝑟𝑒𝑎 𝑜𝑓 𝑓𝑙𝑢𝑥 𝑎𝑡 𝑡ℎ𝑒 𝑎𝑖𝑟 𝑔𝑎𝑝 𝜋𝐷𝐿
𝑡𝑜𝑡𝑎𝑙 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑎𝑚𝑝𝑒𝑟𝑒 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠 𝐼𝑝ℎ 𝑍
specific electric loading 𝑎𝑐 = =3× =
𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑝𝑒𝑟𝑖𝑝ℎ𝑒𝑟𝑦 𝑎𝑡 𝑎𝑖𝑟 𝑔𝑎𝑝 𝜋𝐷
3×2×𝐼𝑝ℎ ×𝑇𝑝ℎ
𝜋𝐷
Choice of Bav (Specific Magnetic Loading)
The following are some of the important factors influencing the choice of ‘Bav’:
i. Iron loss: A higher value of ‘Bav’ means higher flux density in teeth and core. This increases the core loss
decreasing the efficiency and increasing the temperature rise.
ii. Voltage: A machine with high terminal voltage will require more slot space. Hence, the teeth space
reduces. In such cases, a high value of ‘Bav’ is not recommended.
iii. Short circuit current: A machine with lower ‘Bav’ will have higher leakage reactance, resulting in lower
current under short circuit. Hence, to control the short circuit current, it is advisable not to choose higher
‘Bav’.
iv. Stability: Synchronizing power is directly responsible for the stability of the machine. It is also inversely
proportional to synchronous reactance, Xs. A high value of ‘Bav’ gives lower value of Xs , improving the
stability.
v. Parallel operation: Parallel operation of synchronous generators is satisfactory if all the machines in
parallel have a high value of ‘Bav’. Therefore, a high value of ‘Bav’ is recommended in this case.

The usual values of ‘Bav’ assumed are 0.54 to 0.65 Wb/m2 for a cylindrical motor
machine, and 0.52 to 0.65 Wb/m2 for a salient pole machine.
Choice of ac (Specific Electric Loading)
Some important factors influencing the choice of ‘ac’ are given as follows:
i. Temperature rise: A high value of ‘ac’ means increased amount of copper loss,
increasing the temperature rise. Sophisticated cooling methods must be employed
to dissipate the heat.
ii. Voltage: For machines with high terminal voltage, more space is required for
insulation, and so the space for copper is less, and hence high value of ‘ac’ cannot
be assumed.
iii. Synchronous reactance: A high value of ‘ac’ means higher synchronous
reactance, poor voltage regulation, lower short circuit current, and small
synchronizing power.
iv. Stray load loss: A high value of ac leads to higher stray load loss.

The following are the usual values of ‘ac’:

• Turbo generators: 50,000 to 75,000 ampere conductors/m.
• Salient pole machines: 20,000 to 40,000 ampere conductors/m.
Design of Salient Pole
Machine
Main Dimensions
• The stator bore diameter, D and axial length, L are the main dimensions of synchronous machine.
• The outer diameter of rotor Dr is nearly equal to D, as the length of air gap is negligible as
compared with diameter D.
• The selection of D depends on the parameters as shown in Fig. 10
Fig. 10
Types of Poles
Fig. 11
i. Rectangular poles
• Figure 11 shows a rectangular pole.
• The ratio of pole arc to pole pitch varies between 1 and
5.
• This ratio should not exceed 3 for normal machines.
𝑳
= 𝟏 𝒕𝒐 𝟓
𝝉
ii. Round poles
• For round poles shown in Fig. 12, Fig. 12
• the ratio of pole arc (bs) to pole pitch (τ) must lie
between 0.6 and 0.7.
• For round poles with square pole shoes, the length of
pole is equal to the width of pole shoe bs.
• So, L = bs
𝑳
= 𝟎. 𝟔 𝒕𝒐 𝟎. 𝟕
𝝉
Flowchart for calculation
of Main Dimensions:
Peripheral Speed

• The machine should be designed to withstand centrifugal forces

produced at runaway speeds.
• Peripheral speed for salient pole machines varies from 50 to 80
m/s based on the pole attachments.
• Bolted poles: 50 to 80 m/s
• Dove tail / T-heads: 80 m/s
• Turbo generators: varies from 80 to150 m/s.
Length of airgap
• The performance of the machine is greatly influenced by the length of the airgap.
• A machine with longer length of airgap means large value of reluctance to the
flux produced by armature mmf.
• This decreases the synchronous reactance and increases the short circuit ratio
(SCR)
• Such a machine with larger airgap, smaller Xs and higher SCR will be
characterized as having
✓higher stability limit
✓higher synchronizing power, easy tolerance load variations
✓good voltage regulations
✓better cooling
✓lower tooth pulsation losses
✓lower noise level
✓lesser unbalanced magnetic pull
• The length of airgap is related to the pole pitch τ and Table 1 gives the
design values of lg/τ for various synchronous machine.
• Synchronous machines are generally designed with larger airgap
length compared to that of induction motors

Sl. Types of synchronous lg/τ

No. machine
1 Salient pole machine with 0.01 to 0.015
open slot
2 Turbo generators 0.02 to 0.025
3 Synchronous motors 0.02
Flowchart for
determination of
length of air gap:
Pole face profile
• The flux density distribution in the airgap must
be as sinusoidal as possible. Fig. 13

• To achieve this, the length of airgap is not made

constant over the pole arc and it increases from
centre outwards.
• For an exact sinusoidal flux distribution, the
length of airgap at a distance ‘x’ from the centre
is given as follows (Fig. 13):
𝑙𝑔
𝑙𝑔𝑥 = 𝜋𝑥
𝑐𝑜𝑠
𝜏
• For commonly used pole face profiles, a
constant airgap may be maintained to about 0.10
to 0.25 τ on either side of pole centre and then
bevelled to get 1.5 to 2.25 τ at the shoe tips.
 Design of Armature
The design of armature of a salient pole synchronous machine
includes the following:
✓choice of number of stator slots
✓turns per phase
✓cross-section of stator conductor
✓dimension of stator slots
✓length of mean turn
✓stator core depth
✓type of winding and insulation
Choice of number of stator slots
The number of armature slots directly affects the cost and the performance of the machine. Hence,
they have to be properly selected by using the following guidelines:
i. Leakage reactance: With lesser number of slots the conductors are closer, leading to increased
leakage reactance. Therefore, to reduce the leakage reactance, higher number of slots is to be
used.
ii. Tooth flux density: Choice of larger number of slots will lead to narrower teeth resulting in
increased tooth flux density.
iii. Tooth ripple: With larger number of slots, tooth ripple and hence pulsation loss decreases.
iv. Cost: The cost of machine decreases with the reduction in the number of slots, as there are
fewer coils to wind, insulate, place into slots and connect.
v. Hot spot temperature: Choosing lesser number of slots will lead to crowding of conductors
affecting the circulation of air and consequently developing high internal temperature.
vi. Balanced winding: The number of slots should be selected such that a balanced winding is
obtained. The use of unbalanced winding will lead to the generation of space harmonies and
consequent over heating.
The guidelines for the choice of number of slots are given in Table 2.

Parameter Type of machine Value

Slots per pole Salient pole 3 to 4
per phase Non-salient pole 7 to 9
Low voltage machine ≤ 3.5 cm

Slot pitch Medium voltage machine upto 6 kV ≤ 5.5 cm

High voltage machines upto 15 kV ≤ 7.5 cm

Turns per phase of stator winding
• Stator turns per phase,
𝑉𝑝ℎ
𝑇𝑝ℎ =
4.44𝑓𝜑𝑚 𝑘𝑤

where, 𝜑𝑚 = 𝐵𝑎𝑣 𝐿𝜏

• This is the expression used when all the turns of a phase are connected in series.
• In case of larger machines, several parallel paths per phase may be required. In such cases,
the above expression gives the number of turns per phase in one parallel path only.
Area of cross-section of stator conductors
• Stator current per phase
𝒌𝑽𝑨 × 𝟏𝟎𝟑
𝑰𝒑𝒉 =
𝟑 × 𝑽𝒑𝒉
This is the conductor current when all the turns per phase are in series.
• When there are ‘a’ number of parallel paths, then the conductor current is given as follows:
𝑰𝒑𝒉
𝑰𝒛 =
𝒂
• Area of cross-section of stator conductor
𝑰𝒛
𝒂𝒔 =
𝜹
• The value of current density δ depends on speed, type of insulation, type of cooling system and enclosure
used.
• The value of δ for normally cooled machine ranges from 3 to 5 A/mm2, while for machines with
sophisticated cooling systems the value of δ can be used upto 8 A/mm2.
• Higher values of current density will reduce the conductor cross-section, weight and hence cost of the
machine. At the same time, it increases the resistance, copper loss, temperature rise and reduces the efficiency
of machine.
Dimension of stator slot
• The dimensions of stator slot must be selected such that the flux density in the
stator teeth should not exceed 1.8 Tesla.
• Since parallel-sided slots are used, the teeth are tapered having minimum width
Wtmin at the gap surface
𝜑𝑚
𝑊𝑡𝑚𝑖𝑛 =
𝑆𝑠
1.8 × 𝜓 𝐿
𝑝 𝑖
𝑝𝑜𝑙𝑒 𝑎𝑟𝑐
where, 𝜓 =
𝑝𝑜𝑙𝑒 𝑝𝑖𝑡𝑐ℎ
• The depth of slot ‘ ds ’ can be determined by the space requirement for copper
and insulation.
• Normally, the depth of slot is 3 times the width.
• Sometimes deeper slots are used to have higher leakage reactance to reduce
short circuit current.
Length of mean turn

• The length of mean turn for estimating the resistance can be

determined with the help of the following relation
Lmt = 2L + 2.5τ + 0.6×Voltage rating of the machine in kV + 0.2
Stator core depth
• The core flux density is assumed to lie between 1.0 and 1.2 Wb/m2 to find
the depth of core ‘ dc ’ behind the slot
𝜑𝑚
𝑑𝑐 =
2 × 𝐵𝑐 × 𝐿𝑖

• Outer diameter of stator core

𝐷𝑜 = 𝐷 + 2 𝑑𝑠𝑠 + 𝑑𝑐
Type of winding and insulation
• Machines with larger flux per pole will have smaller number of
turns per phase and a double layer winding is used in such cases.
• For machines with lower values of flux per pole and machines
with high voltage rating will have larger number of turns per
phase with multi-turn coils. In such case, either a double layer lap
winding or a single layer concentric winding can be used.
• For double layer winding, open slots are used and for single layer
concentric winding, semi-enclosed slots are used.
• Class B insulation is normally used. Use of class F insulation
makes optimum use of active materials in the machine.
Flowchart for
design of stator:
 Design of Salient pole rotor

The design of rotor includes

✓selection of the pole,
✓height of the pole,
✓design of damper winding,
✓design of field winding
Type of pole
• Laminated poles with laminations of 1.1–1.5 mm thick are used.
• The stacking factor may be taken as 0.95 to 0.98.
• Since the pole carries the useful flux and the leakage flux, the flux density Bp in the pole body may be assumed
between 1.5 and 1.7 Wb/m2 and the leakage coefficient may be assumed between 1.15 and 1.2.
• Area of cross-section of pole body
𝑈𝑠𝑒𝑓𝑢𝑙 𝑓𝑙𝑢𝑥 × 𝑙𝑒𝑎𝑘𝑎𝑔𝑒 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝐴𝑝 =
𝐵𝑝
𝐴𝑝
𝐴𝑝(𝑔𝑟𝑜𝑠𝑠) =
𝑠𝑡𝑎𝑐𝑘𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟
• For rectangular poles, pole body width
𝐴𝑝(𝑔𝑟𝑜𝑠𝑠)
𝑊𝑝 =
𝐿𝑝
Lp=L, since the axial length of 1 pole is equal to stator gross core length.
4𝐴𝑝
• For circular pole 𝑊𝑝 =
𝜋
Height of field winding
𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑 𝑓𝑖𝑒𝑙𝑑 𝑚𝑚𝑓 𝐴𝑇𝑓𝑙
• 𝐶𝑜𝑝𝑝𝑒𝑟 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑓𝑖𝑒𝑙𝑑 𝑤𝑖𝑛𝑑𝑖𝑛𝑔 = =
𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑖𝑒𝑙𝑑 𝑤𝑖𝑛𝑑𝑖𝑛𝑔 𝛿𝑓
(the value of δf may be taken between 3 to 4A/mm2)
𝐶𝑜𝑝𝑝𝑒𝑟 𝑎𝑟𝑒𝑎
• 𝑇𝑜𝑡𝑎𝑙 𝑠𝑝𝑎𝑐𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑤𝑖𝑛𝑑𝑖𝑛𝑔 =
𝑠𝑝𝑎𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
𝑡𝑜𝑡𝑎𝑙 𝑤𝑖𝑛𝑑𝑖𝑛𝑔 𝑎𝑟𝑒𝑎
• Height of winding ℎ𝑓 =
𝑑𝑓

Space
Type of conductors
factor Pole pitch (mm) Winding depth, df (mm)
Strip on edge winding 0.8 to 0.9 0.1 25
Small round wires 0.4 0.2 35
Large round wires 0.65 0.4 45
Large rectangular conductors 0.75
Or,
𝐴𝑇𝑓𝑙 ×10−4
• 𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑖𝑒𝑙𝑑 𝑤𝑖𝑛𝑑𝑖𝑛𝑔, ℎ𝑓 =
𝑆𝑓 𝑑𝑓 𝑞𝑓
where,
Sf = copper space factor
df = depth of winding
qf = loss per unit surface W/m2 = λθ,
where,
1+0.1𝑉𝑎
λ= specific loss dissipation = W/m2-C°
0.08 𝑡𝑜 0.12
θ= permissible temperature rise (value can be taken from standard Table)
Height of Pole
Fig. 14

• Height of pole body ℎ𝑝 = ℎ𝑓 + 0.02

• Radial length of pole ℎ𝑝𝑙 = ℎ𝑓 + ℎ1 + 0.02

where,
height taken by flanges = 20mm = 0.02m
h1 = height of pole shoe (determined from the
pole drawing- Fig. 14)
Design of Damper Winding
Purpose
• In Synchronous Generator
• To suppress the negative sequence field
• To damp the oscillations when the machine starts
hunting
• In Synchronous Motor
• To provide starting torque
• To develop damping power when the machine starts
hunting
• The total area of damper winding is distributed into
smaller cross-sections depending upon the number of
bars used.
• The slot pitch of damper windings made different from
stator slot pitch by about 20% in order to reduce current
induced in damper windings by tooth ripples.
Fig. 15: Damper winding
• 𝑃𝑜𝑙𝑒 𝑎𝑟𝑐 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑎𝑟𝑠 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒 × 𝑦𝑠 × 0.8
• Total area of damper bars per pole
𝜏
𝐴𝑑 = 0.2𝑎𝑐
𝛿𝑑
where, the current density in the damper bars (δd)
is usually taken as 3 to 4A/mm2
• Length of each damper bar
𝐿𝑑 = 1.1𝐿 𝑚 ; for small
machines
𝐿𝑑 = 𝐿 + 0.1 𝑚 ; for larger
machines
• Cross-section of each damper bar
𝑡𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑏𝑎𝑟𝑠 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒 𝐴𝑑
𝑎𝑑 = =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑎𝑚𝑝𝑒𝑟 𝑏𝑎𝑟𝑠 𝑝𝑒𝑟 𝑝𝑜𝑙𝑒 𝑁𝑑
where, Nd = number of damper bars per pole
𝜋 2
• In case of circular bars 𝑎𝑑 = 𝑑𝑑
4
Fig. 15: Damper winding
Where, dd = diameter of damper bars
Design of Field Winding
• Machines with small number of poles:
wire wound coils

• Small alternators having large number of

pole: glass covered rectangular strips

• Large slow speed alternators: strip on

edge winding (Fig. 16) where the bare
copper strips are insulated from each
other by interturn insulation
Fig. 16
• Machines with class-B insulation:
• Interturn insulation consists of 2-layers of treated asbestos paper
• Each layer having a thickness of 0.18 mm
• Straight strips of paper are struck at the sides and at the ends of the coil with either
synthetic resin varnish or shellac
• 10 mm thickness of flanges, made of bakelized asbestos board, are placed at top and
bottom of the coil
• Machines with class-F insulation:
• Interturn insulation consists of 3-layers of thick epoxy treated asbestos paper
• Each layer having a thickness of 0.18 mm
• Paper layers are held by dabbing epoxy adhesive
• 10 mm thickness of flanges i.e., mouldings epoxy resin with glass chopped strand mat,
are placed at top and bottom of the coil
• Pole body insulation is of epoxy glass laminates and is 4 mm thick.
• Step 1:
0.8 𝑡𝑜 0.85 𝑉𝑒
Voltage across each field coil, 𝐸𝑓 =
𝑝
✓Number of field coils are same to number of poles, and all of them are
connected in series
✓The exciter voltage Ve varies between 50 V to 400 V
✓125 V- small and medium size machine, 250V – large size machine
• Step 2
Height of field winding, ℎ𝑓 = ℎ𝑝𝑙 − ℎ1 − 0.02𝑚
• Step 3:
Suitable winding depth df is assumed from table
Pole pitch (mm) Winding depth, df (mm)
0.1 25
0.2 35
0.4 45

Length of mean turn of the coil is calculated by

𝐿𝑚𝑡𝑓 = 2𝐿𝑚 + 𝜋 𝑏𝑝 + 0.01 + 𝑑𝑓
where, Lm=0.9L
Fig. 17: Calculation of Lmtf
• Step 4:
𝐴𝑇𝑓𝑙 𝜌𝐿𝑚𝑡𝑓
Area of field conductors, 𝑎𝑓 =
𝐸𝑓

• Step 5:
Field current, If = current density × area of conductors = 𝛿𝑓 × 𝑎𝑓
(Current density δf can be taken 3 to 4 A/mm2)

• Step 6:
𝐴𝑇𝑓𝑙
Number of turns of field coil 𝑇𝑓 =
𝐼𝑓
• Step 7:
✓Accommodate the field coil turns accordingly.
✓If the available winding space is less, increase the depth.
✓In case of more available space, decrease the depth till the windings fit in.
• Step 8:
• The resistance of the winding at 75°C
𝑇𝑓 𝜌𝐿𝑚𝑡𝑓
𝑅𝑓 =
𝑎𝑓
• Copper loss in each field coil at 75°C
𝑄𝑓 = 𝐼𝑓2 𝑅𝑓
• This loss is to be dissipated by the field coil, and therefore it must be
checked that the temperature rise is within the limits.
 𝑄 𝑓 𝑐𝑓
• Temperature rise , 𝜃=
𝑆
0.08 𝑡𝑜 0.12
where, 𝑐𝑓 = (suitable value is taken) , and 𝑆 = 2𝐿𝑚𝑡𝑓 ℎ𝑓 + 𝑑𝑓
1+0.1𝑉𝑎
• If θ exceeds the limit, increase the depth of winding.

• Step 9:
Finally the clearance between adjacent field coils is checked from the pole
drawing. The minimum clearance between them should be 15 mm.
 Design of Turbo-
Alternators
1. Main dimensions
2. Length of Air-gap
3. Stator Design
4. Rotor Design
1. Main Dimensions
• D is calculated form the specified peripheral speed Va (120-175 m/s).
• L is calculated from the relationship
𝑉𝑎2
𝑄 = 1.11𝐾𝑤 𝐵𝑎𝑣 𝑎𝑐𝐿 × 10−3
𝑛𝑠

For conventionally For large water-

Specific Loadings
cooled generators cooled generators
Bav (Wb/m2) 0.54 to 0.65 0.54 to 0.62
ac (A/m) 50,000 to 75,000 1,80,000 to 2,00,000
2. Length of Air Gap
• Length of air gap
0.5𝑎𝑐𝜏
𝑙𝑔 = × 10−6
𝐾𝑔 𝐵𝑔
For all practical purposes,
Bg is taken as (1.5×Bav)
Kg is taken as 1.1
3. Stator Design
• Number of slots per pole per phase usually lies between 2 to 4, but may be
taken as 8 to 9.
• Slot pitch is normally 25 to 60 mm, but may be taken as 75 to 90 mm.
• Single layer concentric or two layer short-pitched windings may be used.
• Stator conductors must be subdivided and transposed to reduce eddy current
losses.
• Two conductors per slot is assembled in modern large turbo-alternators.
• Two parallel circuits per phase
• Current density in the stator windings
• Water-cooled generators: 8 to 9.5 A/mm2
• Conventionally cooled machines: 4 A/mm2
• Stator winding is deliberately put in deep slots.
 4. Rotor Design
• Rotor winding is not concentrated but is distributed in slots.

• The number of wound slots should be an integer which is a multiple of four

(e.g., 16, 20, 24…)

• Epoxy glass and asbestos moulded resin glass and/or synthetic rubberized
glass are used as insulation. The insulation thickness varies from 0.25 to 0.33
mm per 100 V across the winding.

• Rotor current density may be taken 2.5 A/mm2 for conventionally cooled
machines. However, in modern direct cooled generators the rotor current
densities may be as high as 9.5-14 A/mm2
Rotor winding Design
1. Full load field mmf can be taken as twice the armature mmf
𝐴𝑇𝑓𝑙 = 2𝐴𝑇𝑎
𝐾𝑤
where, 𝐴𝑇𝑎 = 2.7𝐼𝑝ℎ 𝑇𝑝ℎ
𝑝
2. A standard exciter voltage Ve is taken.
0.8 𝑡𝑜 0.85 𝑉𝑒
3. Voltage across each field coil, 𝐸𝑓 =
𝑝
4. Length of mean turn of the field winding is approximated from
𝐿𝑚𝑡𝑓 = 2𝐿 + 2.3𝜏 + 0.24 m , τ = effective span of coils
𝐴𝑇𝑓𝑙 𝜌𝐿𝑚𝑡𝑓
Area of field coil, 𝑎𝑓 = 𝑚𝑚2
𝐸𝑓
5. Number of conductors:
2𝑝𝐴𝑇𝛽
Total area of field conductors =
𝛿𝑓
(assume suitable current density δf for the field winding)
2𝑝𝐴𝑇𝛽
Number of field conductors =
𝛿𝑓 𝑎𝑓
2𝑝𝐴𝑇𝛽
Conductors per slot =
𝛿𝑓 𝑎𝑓 𝑆𝑟
(Sr = number of wound slots in the rotor)