PRESS SH NPUBESESONNHNS ye Se SRN NNN NNN RR RNR NNN RN WRN BRS Seer eee BE CONTENTS CHAPTER 1! PRINCIPLES OF ELECTRICAL MACHINE DESIGN Design of machines Design factors Limitations in design Moilern trends in design of electrical machines Modern manufacturing techniques Basio principles CHAPTER 2 ELECTRICAL ENGINEERING MATERIALS Electrical conducting materials High conductivity materials Copper Aluminium Iron and stcel Alloys of copper Materials of high resistivity Materials used for precision work Materials used for rheotsats ‘Materials used for heating devices Electrical carbon mate ‘Super-conduetivity Magnetic materials ‘Type of mangoetic materials Soft magnetic materials Solid core materials Sheet steels Special purpose alloys Insulating materials Electrical properties of insulating materials Temperature rite of insulating materials Classification of insulating materials Insulating materials ured in modern electric machines Applications of insulating materials Insulating materials for wires Insulating materials for laminations Insulating materials for machines Insulating materials for transformers CHAPTER 3 HEATING AND COOLING OF ELECTRICAL MACHINES Modes of Heat Dissipation Page Mean 29 Meea 2 s13. ou sn Ganscae Beas weEwewe Bar 2S a59 Re 0. 1 3 12. 13. 2. 3. 4. 5, 6. 6: 6 7 BORO EEREEEEEMULELLELY ene SSoseuu Ss Hf 3 3 > 3 rs 3 Sane 3245. 3-246. 5247, Convection Newton's law of cooling Ambient temperature ‘Temperature Gradient Internal temperatures (Hot spot temperatures) Calculation of internal temperature ‘Temperature gradients in cores Heat flow in two dimensions ‘Thermal resistivity of windings ‘Temperature gradients in conductors placed in slots Heating of turbo-alternator rotors Cooling of Rotating Electrical Machines Cooling and astociated terminology Method of cooling Louding system Enclosures for rotating electrical machines Induced and forced ventilation Radial and axial ventilation Radial ventilating system Axial ventilating system Combined axial and radial ventilating system Cooling of totally enclo.ed machines Cooling circuits Cooling of turbo-alternators Air-cooled turbo-alternators Hydrogen covling and hy:rogen cooled turbo-alternators ‘Advantages of hydrogen cooling Hydrogen cooling systea Direet cooling and direct cooled turbo-alternators Advantages of direct cooling Coolants used for direct cooling Direct cooling system Superconducting rotor windings Gooling of water wheel generators Direct water cooled rotor windings Quantity of cooling medium (coolant) Air Hydrogen Water Oil ‘Temperatare rise-time Curves Theory of solid body heating Heating Cooling Rating of machines Selection of motor power rating: ‘Types of duties and ratings Continuous duty Short time duty Intermittent periodic duty Intermittent periodic duty with starting Intermittent periodic duty with starting and braking Gontinuous duty with intermittent periodic uty Continuous duty with starting and brakin, SSSSSSsseayArt, Page 3°25. Ambient temperature and ratings 90 3°26. Overload capacity of motors 91 227. Selection of motor capacity for continuous rating 91 3°28. Methods used for determination of motor rating for variable loads 92 3'28'1. Method of average losses 92 $282. Equivalent current method 93 3'28°3. Equivalent torque and equivalent power methods 94 329." Temperature rise with short time ratings 97 3° 0. Selection of motor capacity for short time rating 97 3°31. Temperature rise of machines with intermittent short time ratings 100 3°32. Selection of motor capacity with short time ratings 103 3°33. Selection of motor capacity for intermittent periodic duty 104 3°34. Rapid heating of conductors 109 3°35, Calculation of hot spot tempcrature 109 3°36. Calculation of surface temperature rise 110 3 Calculation of temperature rise of armatures - Mn 3 Calculation of temperature rise of field coils 112 3 Calculation of temperature rise of commutators 113. 3°37. Measurement of temperature rise 13 3 ‘Methods of measurement of temperature rise us BY Thermometer method M3 3% Resistance method 413 z: Embedded temperature detectors (E.T.D.) na 3°39. Measurement of winding temperature Na CHAPTER 4 BA>IC PRINCIPLES OF MAGNETIC CIRCUITS Basic formulae 118 ‘Magnetization curves 121 ‘Magnetic leakage 12 Magnetic Circuit Calcalations 4°4, Calculation of total mmf 122 4°4.1. Munf for air gap 123, 4°42. Net length of iron 181 4°43. Mnf for teeth 13 4°4°4, Real and apparent flux densities 133 Tron Losses 4 ‘Types of iron losses 142, 4 Hyzteresis losses \2 4 Eddy currents and eddy current losses 4 Eddy current loss in thin sheets \s 45°4, Total iron losses 5, 46. Pulsation losses My Magnetic Leakage Calculations 47. Efscus of leakage fx 13 . ‘Specific permeance 49, Leakage reactance 153 4°10, Armature leakage 154 411. Slot leakage tel sided wr 4°11'1, Specific permeance of parallel sided stots GIL, Specific permeance of tapered slots 159 4'11°3. Specific permeance of circular slots loo= bangnannneoee SERGEERS=555=6=2 = . Senna. ae Pr ESO SAF ASSES NNN SD ee FS BEAangaaanaae : -meance of semi-circular bottom position Sprcitic permeance of closed tJpe of slots Specific slot perm ances for complicated shaped slots Specific permeance of slots with double layer winding Specific permeance of slots of special purpose induction motors Specific permeance of deep bar rotor slots Tooth top leakage Zigzag leakage Overhang leakage Leakage reactance calculations of polyphase machines Leakage with fractional pitch windings Leak ige in salient pole machines Effrct of saturation and load on leakage co-efficient Magnetizing Current Calculatiun of magnetizing current lagnetizing current for concentrated windings Magnctizing current for distributed windings Unbalanced Magnetic Pall Magnetic pull (force) Radial magnetic forces in rotating machines Calculation of unbalanced magnetic pull Effect of saturation on unbalanced magnetic pull Practical aspects of unbalanced magnetic pull Field Form Field form : introduction Air gap flux distribution factor (Field form factor) Harm:nic analysis of Bux distribution curve Rectangular flux distribution curve Actual flux distribution curve CHAPTER 5 BLECTROMAGNETS Introduction Types of electromagnets Flat faced armature type Horse shoe type Flat faced plunger type Construction of electromagnets Electromagnet core materials Electromagnet coils Design of magnet coils Index number of electromagriets Design of flat faced armature type circular magnets Design of a large circular magnet Design of hozse shoe type of magnet Design of plunger type of magnet Magnetic clutches Design of friction clutchCHAPTER 6 ARMATURE WINDINGS Ant. Paye 6L Introduction 228 62. Single and two layer windings 229 6:3. Closed and open windings 230 64. oils and coil sides 230 65. Numbering scheme 230 66. Coil span - 231 67. Typer of d.c. windings 231 6k. Winair.g pitches 231 681. Back pitch 231 682. Front pitch 232 683. Winding pitch 232 684. Commutatar pitch 232 6%." Simplex lap winding 233 69.1. Simplex lap winding with more ti an 2 coil sides per slot 237 610. Simplex wave winding 239 61. Dummy cvils oat 612. Equalizer connections 243 613. Multiplex windings 245 614. Duplex lap windings 246 ois. Duplex wave windings 246 Integrated Approach for Windings 616. Relations beiwean winding pé 247 6 16'1. Conditions for a closed windin; 248 (6:2. Similar parts and number of picallel paths in a winding 249 6163. Equipotential pitch 250 610. Phase pitch 250 6°16°5. Conditions for electrical symmetry 251 6'16'6, Lap and wave windings 251 AC, Armature Windings 617. Introduction 259 6171, Number of phases and phase spread 260 618. Concentric winding 261 6:18'1. Hemitropic winding 261 6182. Whole coil winding 264 6182. Mechanical details of concentric type of coils 267 619. Mush windings 267 620. Double layer windings 270 621. Integral slot lap windings 270 6-22. Integral slot wave windings 273 623. Fractional slot windings 275, 623'1. Layout of fractional slot windings 276 6'23°2. Conditions for electrical balance or symmetry 284 624. Tappings and openings 286 625. Choice of double layer windings 289 6°26. Construction of cvils 290 Production of Emf in Windings 6:27. Emf gencrated in a conductor + 290 5-28, Emf generated in a full pitch coil 292 529, Emf generated in a full pitch distributed winding 293, 5°30, Emf generated in a fractional pitch concentrated winding 294Bees cece een sltSsssaaraR= SSSESSRAT RESETS Y?P Emf generated in a fractional pitch distributed winding Emf generated in a.c. machines Effect of distribution and chording in a ¢, machines Emf generated in d.c. machines Tooth ripples (slot harmonics) Mm Distribution of Armature Windings Mnf d’stribution of concentrated coils Maf distribution in d.c. machines Manf distribution in J phase a.c. machines Eddy Current Losses in Conductors Skin effect Eddy current loss Eddy current loss in a single conductor placed in a slot Eddy current loss in subsiviced (laminated) conductors placed in slots Gritical depth Reduction of eddy currents in conductors in rotating machines Eddy current losses in transformer conductors and their reduction CHAPTER 7 TRANSFORMERS: Introduction Core and shell type transformers Single and three phase transformers Three phase transformer connections Three winding transformers Distribution and power transformers Core Core cross-section Core construction with hot rolled laminations Yoke cross-section Clamping of core Core construction of modern core type power transformers Cooling of cores Core earthing ‘Transformer windings Continuously transposed conductor windings Cooling of transformers Methods of cooling of transformers Transformer tank Cooling due ‘Transformer oi Terminals and leads Bushings an ch ‘appings and tap changii Conservator and breather Temperature indicators Buchholz relay ‘Transformer assembly Desige Output of transformer Output equation—volts per turn Ratio of iron loss to copper loss Page 295 295 296 303 304 305 308 a 318. 320 30 322 325 325 326 331 332 334 337 337 430 339 340 341 342 344 345 447 348. 348 356 357 358 363 363 365 366 367 367 371 372 372 374 315. 376 3778. 3° 3 9, 0. 0" 1. 2. 4. 4, 5. RESRSSRBSEOS SSSSsss FAG AGATA AS esr SSLSRSETSSSS Be between core area and weight of iron and coppei Optimum desi Design for minimum cost Design for minimum loss or maximum efficiency Variation of output and lostes in transformers with linear dimensions Design of core Square and stepped core Calculation of core area Choice of flux density Design of windings Selection of type of winding Position of windings relative to core Design of insulation Surge phi nomenon Surge protection Window space factor Window dimensions ‘Width of window for optimum output Design of yoke Overall dimensions Operating Characterictics Resi.tance of windings Leakage reactance of windings Leakage reactance of core type transformers Leakage reactance of randwich coils Regulation Mechanical forces Calculation of mechanical forces Radial forces Axial forces Forces due to asymmetry Bracing of windings No load current No load current of single phase transformers No load current of three phase transformers Magnetizing volt-amperes Change of parameters with frequency ‘Temperature rise of transformers Transformer oil as a cooling medium ‘Temperature rise in plain walled tanks Design of tank with tubes Air blast cooling Forced oil circulation Thermal rating Momentary overloads Heating time constant of transformers Design of Small Single Phase Transformers tact Gore design Window area Pages 377 378 378 379 380 380 383 383 383 383 985 386 386 391 394 396 396 397 397 398 406 407 410 412 413 414 44 45 416 418 419 419 420 420 423 425, 425 425 426 a7 431 432 40 431 451 451Art. sone Bennnecareramnac Gonoccoeeeeee Seg SEeeoeoweoovovqeoy SS35 eove ol4. via CHAPTER 8 GENERAL CONCEPTS AND CONSTRAINTS ‘ OF DESIGN OF ROTATING MACHINES Relation between rating and dimensions of rotating machines Symbols Main dimensions ‘Total loadings Specific loadings Output co efficient Factors affecting size of rotating machines Choice of specific magnetic loading Choice of specific electric loading Variation of output and losses with linear dimensions Separation of D and L Separation of D and Z for d.c. machines Separation of D and L for induetion motors Separation of D and L for synchronous machines Standard frames CHAPTER 9 D, C. MACHINES Tnteoduetion and Applications Classification Constructional details Stator Poles Interpoles Main field winding Interpole winding Armature Armature winding Commutator Brush gear Brush holders Brush rockers Brushes Methods of applying brushes to commutators Staggering of brushes Frames Constructional features of motors fed from static converters Design Output equation Choice of average gap density Choice of ampere conductors per metre Interdependence of specific magnetic and electric loadings Selection of number of poles Guiding factors for choice of number of poles Core length Limiting value of core length Armature diameter Limiting value for armature diameter Page 454 454 454 454 455 455 437 458 460 466 468 468 413 470 471 4a 402 483 483 484 484 485 485 486 487 488 488 489 489 489 491 493 493 495, 497 497 508 504 505Page Pole proportions 506 Number of ventilating ducts 506 Length of Air gap 507 Estimation of air gap length 507 Pole face profile 507 Armature Reaction 9°18. Flux distribution on load 513 919, Effect of armature reaction 515, 920. Brush shift and its effects 515 9°21. Reduction of effccis of armature reaction 56 Armatore Design 922. Choice of armature winding 519 923. Number of armature conductors 320 9°24. Number of armature coils 521 925. Number of armature slots 523 9.25°1. Guiding factors for choice of number of armature slots 524 9°26, | Cross-section of armature conductors 305 9°27. Insulation of armature winding 526 9°28, Slot dlimensions 307 9:29, Armature voltage drop 529 930. Depth of armature core 529 Design of Field System Pole Design 539 Area of poles 539 Height of pole 539 Tentative design of field winding 540 Yoke 541 |. Magnetic circuit 342 Magnetization curve (0.C.C.) 543 1 of shunt field winding 544 Design of series field winding 545 Commutation 9°37, Commutation phenomenon 552 9°38. Form of current in coil undergoing commutation 353 9'38'1. Resistance commutation 358 9°38'°2, Retarded commutation 36 9383. Accelerated commutation 357 9'33°4, Sinusoidal commutation 557 Design of Interpoles 939. _Interpoles 580 o4. Time of commutation 558 941. Width of commutation zone 361 9°42. Width of interpole shoe 561 943° Calculation of reactance voltage 561 9°44. Pitchelmayer's equation 563 945 Length of interpole 364 9°46, Flux density under interpole shoe 564 9°47. Design of interpole winding 364loan, 10°22. 10°22"1. 10°22°2. 10°28. 10°23°1. 10°23'2, 10°23'3. 10°23°4, 1024, Design of Commutator and Brashes Number of segments Commutator diameter Length of commutator Dimensions of brushes Losses of commutator surface Losses and Efficiency Losses and efficiency Rotational losses TR losses Stray load losses Efficiency Temperature rise CHAPTER 10 THREE PHASE INDUCTION MOTORS Introduction Stator Stator frames Rotor Rotor winding Comparison of squirrel cage and wound rotors Slip rings Shaft and bearings Design Output equation Choice of average flux density in air gap Choice of ampere conductors per metre Efficiency and power factor Main dimensions Stator winding . Turns per phase . Stator conductors Shape of atator slots Number of stator slots Area of stator slots Length of mean turn Stator teeth Stator core . Rotor Design Length of air gap Relations for calculation of length of air gap Design of Squirrel Cage Rotor Number of rotor slots Roles for selecting rotor slots Reduetion of harmonic torques Design of rotor bars and slots Rotor bar current Area of rotor bars Shape and size of rotor slots Rotor alot inwulation Desiga of end rings 568 569 569 570 575, 576 516 576 377 594 594 595 597 599 600 600 601 601 601 602 603 605 605 606 613 614 615 618 619 622 623 623Art, 10°24"1 10°24°2, 10°24°3, 1025. 10°25'1. 10252. 10°53. 10.25°4, 10°26. 1097 10°28, 10 28. 10°28'1, 10 282. 10°25 1 29'1, 10292, 10°29'3, 10°30. End ring current Area of end rings Full load slip Design of wound rotor Number of rotor slots Number of rotor turns Area of rotor conductors Rotor windings Rotor teeth Rotor core Szies of induction motor laminations available in the market Operating Characteristics No load current Magnetizing current ‘Loss component Short circuit (blocked rotor) current Stator resistance Rotor resistance Leakage reactance Gircle diagram Calculition of maximum outpnt from geometry of circle diagram Dispersion coefficient . Effect of dispersion coefficient on maximum power factor . Effect of dispersion coefficient on overload capacity . Effect of change of air gap length Effect of change of number of poles . Effect of change of frequency Rel tion between D and L for best power factor Mcthous of improving starting torque Double cage rotor - Deep bar rotor Lo 2 A and efficiency itional losses Temperature rise CHAPTER 11 SINGLE PHASE INDUCTION MOTORS General Information and Constractional Details Introduction ‘Types of motors Split phase starting Shaded pole starting Repulsion motor starting Construction Stator Stator windings Rotor Starting switches Electrolytic capacitor 623 625 625 628 628 628 628 629 630 630 632 632 632 638 638 639 642 645 648. 648 649 650 651 651 653 653 654 655 655 655 656 687 687 687 692 692Design Output equation Choice of spevific loadings Main dimensions Relative size of single phase and three phase motors Design of stator Running winding (main winding) Number of turns in running winding Running winding conductors Number of stator slots Size of stator slot Stator teeth Stator core Length of mean turn Air gap length Design of rotor Number of rotor slots Area of rotor bars Area of end ring Rotor resistance Rotor teeth Operating Characteristics Mnf for air gap Saturation factor Tron loss Friction and windage loss Parameters . Running winding resistance 2. Rotor resistance 3. Leakage reactance calculation of single phase motors Running performance . Equivalent circuit 2. Veinott’s method Pull-out torque Starting (Auxiliary) Winding Design of starting winding for split phase mots . Starting torque Gircle diagram Maximum starting torque |. Maximum torque per ampere f starting winding for capacitor stator niotor nce for maximum torque - Capacitance for maximum torque per ampere CHAPTER 12 SYNCHRONOUS MACHINES Type of construction ‘Type of synchronous machines Prime movers for synchronous gencrators Run-away speed Constuction of hydro generators Stator core 692 693 693 693 694 696 697 697 698 698 698 698 698 698 996 007 007 700 700 701 701 701 7a 702 703 703 704 706 706 708 709 no 710 mu 722 723 123, 725 725 7251252. 1253 1254 1255. 1256 1257, 15H 1259, 125710 126 1261 1262. 1263 127, 12°8. 1281, 1282. 2. Mult Stator winding Bracing of stator overhang «Rotor body Poles winding Damp: winding Bearings Brakes and Jacks Slip rings Construction of turbo-alternators Stator core Stator winding Rotor Industrial generators Design Ontput equation Choice of specific magnetic loading Choice of specific cleetric loading Design of Salient Pole Machines Main dimensions Short circuit ratio Effcct of SCR on machine performance Length of air gap Shape of pole face Armature design + Comparis nm between single and double layer windings umber of armature slots . Coil span ‘Turns per phase 2 Conductor seetion Armature windings, coils and their insulation Single turn bar~class B urn coil—class B Synthetic resin and mica paper insulation Slot dimensions Length of mean turn Stator coi Elunination of harmonics Armature parameters ‘1. Armature resistance 2. Armature leakage reactance Estimation of air gap length Design of rotor » Height of pole . Design of damper winding . Height of pole shoe . Pole profile drawing Magnetic circuit Open circuit characteristica Determination of full load field mmf Design of field winding Determination of direct and quadrature axis synchronous reactances ny 728 79 730 731 731 732 732 732 732 732 733 733 735 736 736 736 737 740 741 Tal 742 742 742 743 744 744 144 744 744 747 747 748 8 74 749 753 753 754 755 758 758 761 762 762 763 165,Art, 12°27. 12°28. 12°29 12°30. 1231 12°32 17°33, 131 132. 13211 1322 13.23. 133, SR RSE Short circuit charscteristics Losces Vemperature rise Degsin of Tarbo-alternators Main dimensions Length of air gap Stator design Rotor design CHAPTER 13 STARTERS AND FIELD REGULATORS Motor starters ¢ alenlation of resistance steps Starters for dc. shunt motors Starters for d c. series motors Starters for three phase slip ring induction motors Field regulators CHAPTER 14 DESIGN OF ELECTRICAL APPARATUS Design of resistance cloments of field regulators Materials for resistnce elements Size of wire Resi ance box 7 of resistances for starters for shunt motors Design of loading rheostats Design of grid resistances Design of lieating elements Design of Chokes Design procedure Design of Welding Transformore Characteristios of welding transformers ‘Types of welding transformers Electric arc Series reactance Design of Current Transformers Introduction Errors Construction Design principles + Gore “2. Secondary current rating “3, Primary current rating -4, Windings Behaviour of transformer under system short circuit Turns compensation Design of Permaneat Magnets Permanent magnet materials Design procedure 773 74 774 715 775 776 778 804 804 805 808 810 813 a7 8i7 817 318 819 821 822 824 825, 828 828 829 831 831 833 835 835 836 136 £37 837 B44Ant. TL 172, 333 Ss3 CHAPTER 15 DESIGN OF MECHANICAL PARTS Design of shaft Bearings Sleeve bearings ‘Anti friction bearings Shaft couplings Frames for d.c. machines Frames for ac. machines Centrifugal force Bracing of rotor windings Wire bands of rotors Solid bands (retaining rings) ‘Wedges Stresses in poles bolted on to rims Stresses in dove-tailed poles Stresses in turbo-alt-rnator rotors Stresses at the bottom of teeth Stresses in rotor d sc Critical speed Inertia constant Mechanical design of commutators Design of fan CHAPTER 16 COMPUTER AIDED DESIGN Introduction Advantages of digital computers Computer aided desiga—different approaches Analysis method Synthesis method Hybrid method Optimization General procedure for optimization Yariables and | constraints lomputer lesign of three phase induction motor: List of symbols used” motors General design procedure CHAPTER 17 STANDARD SPECIFICATIONS Conductors Indian standard specifications for copper conductors used in electrical machines and apparatus British standard specifications ‘Transformers General Outdoor type distribution transformers IS : 1180—1966 Power transformers (IS : 2026—1962) 847 847 847 848. 850 851 851 852 854 856 856 857 857 828 800 861 SESRSSRE 8 en 870 875176. 177. 178, 179. 17-10. ITH. Rotating Machinery Recommendations for rotating electrical machinery Recommendations on determination of efficiency of rotating electrical machines Recommendation for preferred standard 3000 rev/min 3-phare 50 Ha turbine type generators Three Phase Induction Motors Indian standard specifications for 3-phase induction motors Single Phase Induction Motors Indian standard specifications for single phase small a c. and universal motors Current Transformers Indian standard specifications for current transformers ITN, Terminology gio 915 915