ACKNOWLEDGEMENT

An engineer with only theoretical knowledge is not a complete engineer. Practical knowledge is very important to develop and apply engineering skills. It gives me a great pleasure to have an opportunityto acknowledge and to express gratitude to those who were associated with me during my training at BHEL. Special thanks to Mr. P.S. Jangpangi Sir for providing me with an opportunity to undergo training under his guidance. I am very grateful to our traning officer Mr. Arup Chakrobarty for his support. I express my sincere thanks and gratitude BHEL authorities for allowing me to undergo the training in this prestigious organization. I will always remain indebted to them for their constant interest and excellent guidance in my training work, moreover for providing me with an opportunity to work and gain experience.

RAVINDER SAINI

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Table of Contents
BHEL:
AN OVERVIEW............................................................................................ 4 Power Generation............................................................................................ 6 Heavy Electrical Equipment Plant.................................................................12 ELECTRICAL MACHINES BLOCK(BLOCK-I) ...................................... 14 Introduction .................................................................................................. 14 Plant Details ................................................................................................. 15 Stator body 15 Stator winding And insulation16 ROTOR ................................................ 18 Rotor .............................................................................................................22 Rotor winding............................................................................................... 23 Sliprings, Brushgears and shaft Earthing..27 Safety Precautions..30 Emergency Procedure....31 CONCLUSION ...............................................................................................32 Bibliography ............................................................................................ .......32

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BHEL: AN OVERVIEW BHEL is the largest engine energy related/infrastructure sector. BHEL was established more than 40 years ago, ushering in the indigenous Heavy Electrical Equipment industry in India, a dream which has been more than released with a well-recognized track record of performance. It has been earning profits continuously since 1971-72.BHEL caters to core sectors of India economy viz. Power Generation and Transmission, Renewable Energy, Defense etc. The wide network of BHELs 14 manufacturing divisions, 4 power sector regional centers, 8 service centers, 15 regional offices and a large number of projects sites spread all over India and abroad enables the company to promptly serve as customer and provide them with suitable products, systems and services- efficiently and at competitive prices. BHEL has attained ISO 9001:2000 certifications for quality management and all the manufacturing units divisions of BHEL have been upgraded to the latest ISO 9001:2000version. All the major units divisions of BHEL have been awarded ISO 14001 certification for Environmental Management System and OHSAS-18001 certification for Occupational Health and Safety management System. BHEL become the first public sector Company in the country to win the coveted prize for in Haridwar unit under the CII Exim Award for the business excellence as per the globally recognized model of European Foundation for quality management. BHEL is the only PSU among the 12 Indian Companies to figure in Forbes Asia Fabulous 50 list. It has also won the Business standard star Public Sector Company Award 2006. The company received MoU Excellence award for 2004-2005 and Merit Certificate for MoU Excellence for 2005-2006.

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STATE OF PLANT :
Generator Erection complete and satisfactory. All erection test results/log sheets available for the following : Mounting of embedded parts and foundation plates. Erection of stator. Gas tightness and Hydraulic tests. Measurement of insulation resistances of various parts of generator, D.C. resistances and impedances. Continuity, D.C. resistance and IR checks of RTDs. Purge tests of rotor ventilation canals. Rotor insertion tests. Bearing adjustment tests. Alignment or generator rotor. Inclination or shaft journal test results. Coupling alignment results of generator and LP rotor. Magnetic Axis adjustment results. Fan and shield clearance results. DTI checks on generator rotor. Shaft seal adjustment results. Temperature monitoring system. Centering and offset-setting of brush gear. Fixing of brush holder and brushes.
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Following Testing/Commissioning schedules completed satisfactorily and results/records available : Generator Gas Tightness Test. Hydraulic test and oil flushing of seal oil system. Seal Oil System Circulation Hydraulic test and flushing of primary water system.

All the systems mentioned in 7.2 are in totally normalised condition and available for generator testing. Fire protection system (CO2 system) is made available

Power Generation
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Power generation Sector comprises Thermal Gas, Hydrogen, Nuclear power plant business. As of 31.3.2007. BHEL supplied sets accounts for 80,781 MW or nearly 65% of the total install capacity of 1, 25,414 MW in the country. Significantly these sets contribute 73% of the total power generated in the country. BHEL has proven turnkey capabilities for executing power projects from concepts to commissioning. It possesses the technology and capability to produce Thermal sets with super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up to300 MW units rating. Co-generating and combined cycle plants have been introduced to achieve higher plant efficiencies. To make efficient use of the high-ash-content coal available in India. BHEL also supplies circulating Fluidized Bed Combustion (CFBC) boilers for thermal plants. The company has proven expertise in Plant Performance Improvement through renovation, modernization and upgrading of a variety of Power plant equipment, besides specialized know-how of residual life assessment health diagnostics and life extension of plants. Overall, BHEL built Thermal sets achieved the highest ever PLH of 78.3% in 2006-2007 which is 2.5% higher than the National average. The combined operating availability of these sets was 84.7%. In fig. is a reminder of the components of a turbine/generator system. Here it includes the exciter which provides DC current to the rotor of the generator.

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Synchronous Generator Theory Synchronous means that the generators rotor runs at the constant mains frequency as load varies.

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Electromagnetic Induction The instantaneous voltage induced in a stator conductor is given by; dB e kl dt = where; k = constant l = length of conductor dB dt = rate of change of magnetic flux density If e is to be a sinusoid, dB/dt must also be sinusoidal. Excitation coils are wound on the rotor to produce a flux with a density which varies approximately sinusoidally around the circumference. A two-pole arrangement (one pole pair) is shown in Fig. The magnitude of the flux density can be changed by varying the direct current to the excitation coils on the rotor.

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Production of sinusoidal voltage (from MPSP).

Speed, Frequency and Pole Pairs If f = frequency, Hz n = rotational speed, r/s p = number of pole pairs Then f = pn In Australia, generators are 2-pole (i.e. p = 1). Hence generators run at 3000 rpm. Three-phase Windings
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Fig. shows how three phases are generated by having three winding spaces on the stator. This is still a 2-pole generator. It is economical to have many stator conductors in parallel so the individual conductor voltages are additive. Each go conductor is connected to a return conductor, acted on by the pole of opposite polarity, and thence to a third conductor adjacent to the first, and so on through the phase. The return conductors are disposed in a layer displaced radially from the go conductor, both in the slots and in the end region. The discrete nature of the windings gives rise to generation of harmonics.

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Arrangement of stator conductors (from MPSP).

Torque The mechanical torque provided by the turbine is balanced by an electromagnetic torque caused by the interaction of the magnetic flux and the current flowing in the stator windings

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Heavy Electrical Equipment Plant BHEL's Heavy Electrical Equipment Plant (HEEP) was set up in technical collaboration with USSR, for the manufacturing of power plant equipment, AC/DC motors of various rating with associated control equipment and started production in January 1967. In 1976, BHEL entered into a collaboration agreement with M/s Kraftwerk Union, AG of Germany for design, manufacturing, erection and commissioning of large size steam turbines. More than40 percent of the country's electrical energy is generated from the power equipment supplied by BHEL, Haridwar. BHEL offer wide ranging products and systems for T & D applications. Products manufactured include power transformers, instrument transformers, dry type transformers, series and stunt reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears and insulators. The products, which are manufactured in HEEP, are: - Steam Turbines, Turbo Generators, hydro turbines, Gas turbines, etc.

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ELECTRICAL MACHINES BLOCK(BLOCK-I)

Introduction

Turbo Generator
500MW Turbo generators at a glance2-poles machines with the following features: Direct cooling of stator winding with water. Direct hydrogen cooling for rotor. Micalastic insulation system. Spring mounted core housing for effective transmission of vibrations. Brushless Excitation System. Vertical hydrogen cooler. Salient technical data:

Rated output

: : : : : :

588MVA,500MW 21KV 16KA 50Hz 0.855Lag 98.55%

1

Terminal voltage Rated stator current Rated frequency

Rated power factor

Efficiency

Important dimensions and weights:

Heaviest lift of generator stator

255Tons
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 Rotor weight

: : : :

68Tons 8.83m*4.1m*4.02m 1.15m and 12.11m 428 Tons

Overall stator dimensions(L*B*H)

Rotor dimensions(Dia. And Length) Total weight of turbo generator

PLANT DETAILS :

The 500 MW generator is coupled to the 500 MW KWU turbine. The rated parameters of the generator are listed in plant details (Section-1) of Testing schedule for generator protection and generator bay. The design and constructional features are outlined briefly below. Generator manual supplied by the manufacturer may be referred for details of above. STATOR BODY : The stator body is a totally enclosed gas tight fabricated structure suitably ribbed internally to ensure high rigidity. Hydrogen coolers are housed longitudinally inside the stator body. Rigid end shields close the casing and support the fan shields.

STATOR CORE : The stator core is made up of segmental varnish insulated punchings of cold rolled grain oriented silicon gel and is assembled in an interleaved
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manner on core bars. Steel spacers for ventilating ducts are provided for radial cooling of core by hydrogen.

The core is held pressed by means of heavy non-magnetic steel press rings which are bolted to the ends of the core bars. Additional support is provided to the teeth portion. In order to isolate the stator body and thus the foundations from magnetic vibrations, the core bars are designed to provide elastic suspension of the core in the stator frame.

STATOR WINDING AND INSULATION:

The stator has a three phase, double layer short corded bar type windings having two parallel paths. Each coil side consists of glass insulated solid and hollow conductors with cooling water passing through the latter. The elementary conductors are Rosbel transposed in the slot portion to minimize eddy current losses. The coil sides are firmly held in position by fibrous slot wedges. The overhang portion of the coil is securely lashed with glass chord to bondage rings and special brackets of non-magnetic steel, which are in turn fixed to the core press rings.

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DISTILLATE HEADERS:

Ring type water headers, made of copper are provided separately for distillate inlet and outlet in the stator on turbine side. The headers are supported on insulators and isolated from stator body. The winding ends are solidly soldered into the coil legs which are then ultrasonically tested. Individual bars are provided with water inlet/outlet connections made of P.T.F.E Hoses, The bar heads are insulated by fiber molded covers.

TERMINAL BUSHINGS:

Water cooled terminal bushings are housed in the lower part of the stator on the slip ring side, Porcelain insulators are provided to insulate the terminal bars from the stator body. Effective sealing is provided between the terminal bushings and the stator body to avoid any possible leakage of hydrogen. Terminal bushings are housed inside a chamber made of non-magnetic steel plates. Three phase terminals and three
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neutral terminals are brought out. The terminal plate of the end terminals, where bus bar connections are made is silver plated.

ROTOR:

The rotor is of cylindrical type; the shaft and body being forged in one piece from chromium nickel molybdenum and vanadium steel. The rotor with all the details assembled is dynamically balanced to a high degree of accuracy subjected to 20% over speed for 2 minutes.

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FIELD WINDING:

The field winding is made from hard drawn silver bearing copper. The winding is held in position and by non-magnetic rotating ring in the overhang portion. Gap pickup method is used for direct hydrogen cooling of rotor.
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The main slot insulation is of glass cloth impregnated with Epoxy resin. The inter turn insulation consists of layers of prepped glass cloth glued to the bottom of each conductor. The end windings are packed with blocks of glass laminates to separate and support the coils and to restrict their movement under stress. The end windings are insulated from the retaining rings with the help of glass epoxy molded segments.

SHAFT MOUNTED FANS:-

For circulating the cooling gas inside the generator two propeller type fans are shaft mounted on either end of the rotor body. Fan hubs are made of alloy steel forging and are a shrunk fit on the rotor shaft. The alloy steel cast fan blades are machined in the tail portion to suit the fan hub and held in position with the help of conical pins.

The blades can be easily removed from or assembled in the fan hub. Fan shields fixed to the end shields guide the gas flow.

RETAINING RINGS:

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The end windings are held in position by retaining rings of floating type shrunk fit on the rotor body. The rings are screwed to prevent axial movement by locking nuts.

SLIP RINGS: The slip rings consists of helically grooved alloy steel rings shrunk on the rotor shaft and insulated from it. They are mounted on a single, common steel bush, which has an insulating jacket pre-molded on it. The complete bush with sliprings are provided with inclined holes for self ventilation. The helical grooves cut on the outer surface help improve the brush performance. FIELD LEAD: The slip rings are connected to the field winding through semi-flexible copper leads and current carrying bolts, placed radially in the shaft. Two semicircular hard copper bars insulated from each other and from the rotor shaft are placed in the central bore or the rotor joining the two sets of current carrying bolts with special profiled precision conical threads.

GAS COOLERS:

Four longitudinally mounted gas coolers are mounted in the stator body. They are made out of admiralty brass with coiled copper wire wound on them staggered form so as to expose maximum surface area to hydrogen.
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BEARINGS: Generator bearings are of pedestal type with spherical seating to allow self alignment and are supported on a separate pedestal on slip ring side and in the L.P casing on the turbine side, Bearing bush is of cast steel lined with white metal. Oil catchers and deflectors are provided to prevent axial leakage of oil. To prevent shaft currents slip ring side bearing and connecting pipes are insulated from earth.

SHAFT SEALS: In order to prevent leakage of hydrogen from the generator casing radial thrust type shaft seals are provided on either side where the shaft extends out from the generator. The seal consists of seal liner with babbit pressing against the shaft caller of the rotor. Seals are defined in testing schedule of seal oil system.

ROTOR: The rotor must: carry the excitation windings provide a low reluctance path for the magnetic flux transfer the rated torque from the turbine to the electromagnetic reaction at the air gap resist large centrifugal forces.
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Steel is the most suitable material. A steel forging is used with machined slots (Fig.).

Rotor section

The winding slots are cut in diametrically opposite pairs over about two-thirds of the circumference, leaving the pole faces without winding slots (Fig.). Equalising slots are cut across the pole faces to avoid a difference in stiffness in two orthogonal directions which would produce a twice-per-revolution vibration. The rotor shaft and the coupling must be designed to withstand four to five times full-load torque in the event of a sudden short circuit.

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Journal bearings are used.

ROTOR WINDDING: Full detail of the winding of a rotor is shown in Fig. Winding coils are assembled into diametrically opposite pairs of rotor slots symmetrically distributed about the pole axis, but in the opposite senses in the two poles; i.e. clockwise current for the north pole and counterclockwise current for the south pole.

Each coil must be assembled as a half-turn, with brazed joints in the end turns (end windings). There are usually one or two turns in the width of a slot. Axial passages and radial holes in the copper conductors provide for forced cooling with hydrogen. The high rotational speed causes hydrogen to flow axially from both ends and radially outwards. Fans mounted on the rotor, primarily to circulate hydrogen though the stator, help the flow through the rotor (Fig.). Insulation is achieved with slot liners of glassfibre material Thick end rings are used to restrain the rotor end winding under the action of entrifugal force. The ends of the
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windings are connected to flexible leads and there are radial copper studs to connect to the sliprings and thence to the exciter. The contents of the winding slots are retrained by an aluminium wedge.

Rotor winding (from MPSP).

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SLIPRINGS, BRUSHGEAR AND SHAFT EARTHING: For a 500 MW generator the excitation current is about 5000 A. This must flow through sliprings with a large area (Figs). Brushes only last about six months but they can be changed while running on-load. In normal operation there is 10-50 volts between the two shaft ends of a generator, due mainly to magnetic dissymmetry. To stop an axial
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current from flowing and damaging bearings, an insulation barrier is provided at the exciter end.

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It is important that the shaft at the turbine end of the generator is maintained at earth potential, using a pair of shaft-riding brushes connected to earth through a resistor. The voltage at the exciter end is monitored as an indication that insulation is intact.

TESTING OBJECTIVE :
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To test the generator equipment and make it ready for excitation and synchronization.

PROPOSAL:
Tests as detailed in item-8 shall be carried out on generator, confirming the manufacturers test reports. Insulation resistance tests on generator rotor, stator and bearing pedestals shall be carried out. Winding resistances for both stator and rotor will be measured and recorded. Impedance of rotor windings shall be measured and recorded. Checks/Tests shall be carried out all the embedded resistance temperature detectors. The brush gear assembly shall be checked tested as per its standard checklist and test procedure.

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SERVICES REQUIRED

Laboratory equipments/test sets for measurement of electrical parameters required in specific tests (5KV motorized megger, Kelvins bridge or micro ohm meter). Illumination at required locations. 240 V A.C power supply for testing. Communication facility at test area.

S A F E T Y PRECAUTIONS:
The test area shall be clearly defined and cordoned off. The test team leader is fully aware of the nature, ocation, and probable duration of the tests. The other agencies working in the test area are informed about the test in progress.

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EMERGENCY PROCEDURE :
Shock treatment chart and first aid box shall be available. Emergency telephone numbers of fire and hospital shall be prominently displayed near by. The test in progress shall immediately be stopped and all line apparatus disconnected and equipment suitably earthed in case of a accident or abnormality. Such instruction will be received from the team leader. The test team is fully aware of measures to be taken in the event of injuries to any personnel / damage to any machinery.

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CONSTRUCTIONAL FEATURES OF ROTOR

The rotor comprises of the following components: Rotor shaft Rotor winding Rotor wedge and other locating parts for winding Retaining rings Fans

Field lead connectio n.

CONCLUSION
The second phase of training has proved to be quite faithful.It proved an opportunity for encounter with such huge machines like turbo-generator hydro generators etc. The architecture of BHEL, the way various units are linked and the way working of whole plants is controlled make the realize that Engineering is not just structural description ,but greater part is planning and management.It provides an opportunity to learn tech. Used at proper place and time can save a lot of labor. However, training has proved to be satisfactory.It has allowed us an opportunity to get an exposure of the practical implementation of theoretical fundamentals.

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BIBLIOGRAPHY
1. 2. 3. 4.

5.

El e ct ri c al ma c hi ne s by B.L. T hr ej a . Electrical Machines by V.K. Mehta. El e ct ri c al ma c hi ne s by As hfa q Hus a i n. Electro Mechanical Energy Conversion by P.S. Bhimra. Electrical Engineering by B.L. Threja

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