Manufacturing and testing process of ***************turbo generators*****************

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A Mini Project Work Submitted in partial fulfillment of the Requirements for the award of degree of

BACHELOR OF TECHNOLOGY
In

ELECTRICAL & ELECTRONICS ENGINEERING

By:

J.DIVYA TEJASWINI(08731A0211) G.MAHESH(08731A0216) G.V.K VAISHNAVI(08731A0257) A.SAI KEERTHAN REDDY(08731A0265)

UNDER THE GUIDANCE OF:

K.MANOJ SIVA KUMAR

Assistant Professor

Dept. of Electrical & Electronics Engineering

Certificate
This is to certify that the project entitled STUDY OF MANUFACTURING AND TESTING PROCESS OF TURBO GENERATORS is submitted by:

J.DIVYA TEJASWINI(08731A0211) G.MAHESH(08731A0216) G.V.K .VAISHNAVI (08731A0257) A.SAI KEERTHAN REDDY(08731A0265) In partial fulfillment of the award of BACHELOR OF TECHNOLOGY at JAWAHJARLAL NEHRU TECHNOLOGICAL UNIVERSITY in record of bonafied work carried out by them under my guidance and supervision.

The result embodied in this project that has not been submitted to any other university or institute for the award of any degree.

ACKNOLWEDGEMENT
We take this opportunity to record our gratitude to all those who helped us in successful completion of the project. We take immense pleasure in thanking Prof. B.RADHAKRISHNAPrincipal of our college and Associate Prof. P.V.RAMKUMAR, Head of the department for having permitted us to carry out this project. We wish to express our deep sense of gratitude to our Internal Guide Assistant Prof. N.USHA for her able guidance and useful suggestions, which helped us in completing the project work in time. We immensely are grateful to Sri. B. PRASADA RAO, CEO (chief executive officer) of BHARAT HEAVY ELECTRICALS LIMITED for giving us permission for undergoing study project training in their company.

We wish to thank Sri MEENAL RUPAM DADEL, SR.EXECUTIVE (HR), and BHEL for allotting us this project. We also wish to thank Sri. PRABHAKRA RAO RB, Sr. Manager, EM (Production), BHEL for his time to time needed valuable guidance. Finally, we wish to express our profound thanks to all the employees, in charges and workmen without whose support, completion of this project would have been impossible.

We express our deep sense of gratitude to our beloved Parents and Friends for giving us moral support and encouragement which helped us in completion of this project.

ABSTRACT
BHEL is the largest engineering and manufacturing enterprise in India in the energy related infrastructure sector today which manufactures turbo generators (2-pole and 4-pole) ranging up to 150 MHz The manufacturing process of turbo generator is mainly divided into stator section and rotor section where stator frame, stator core, stator windings, end covers are received from the stator building section and rotor with rotor windings and rotor retaining rings is received from rotor section and assembled at the assembly section. Each and every process is carried out in a sequential process. Turbo generators are designed with the Closed circuit air cooling with water or air coolers mounted in the pit. The layout of the manufacturing plant is such that it is well streamlined to enable smooth material flow from the raw material stages to finished goods. The raw material that are produced for manufacture are used only after thorough material testing in the testing lab and with strict quality checks at various stages of productions. Latest technologies like vacuum press impregnated moralistic

high voltage insulation, polyester fleece tape impregnation for outer corona protection are implemented to produce high quality insulation for turbines, outstanding performance and long lasting lifetime. TESTING: Testing has to be done on a machine at every step in its manufacturing process for the company to certify it to be a deliverable good. Test brings out the impact of process variations. Testing is done in simulations which tend to closely resemble the practical scenario under which the machine works. Testing provides the experimental data like the efficiency, losses, characteristics, temperature limits etc. In this report of mine we shall look into the different types of tests, which are currently in use at BHEL, which are being conducted on stator, rotor and exciter.

INDEX
Chapter1 . 1-2 1. Introduction 1.1 ABOUT THE COMPANY: BHARAT HEAVY ELECTRICALS
LIMITED.

1.2 History of Turbo Generators 1.3 Principle of operation 1.4 Synchronous generators classification based on the medium used for generation 1.5 Components of Turbo Generator 1.5.1 Stator 1.5.2 Insulation 1.5.3 Rotor Chapter2 . 1-2 2. Manufacturing of components 2.1 Stator 2.1.1 Stator frame 2.1.2 Stator core 2.1.3 Stator windings 2.2 Insulation

2.2 1 Insulation system 2.2.2 VPI system 2.2.3 Process of VPI 2.3 Rotor 2.3.1 Rotor shaft 2.3.2 Rotor winding 2.3.3 Rotor retaining rings 2.3.4 Rotor fans 2.3.5 Bearings Chapter3 . 1-2 3. Assembling of components 3.1 Ventilation 3.2 Cooling 3.3. Excitation system 3.4 Assembly Chapter4 . 1-2 4. Testing 4.1 Types of testing
4.2 List of process tests 4.3 List of performance tests 4.4 List of type tests 4.5 Stator testing 4.6 Rotor testing 4.7 Exciter testing 4.8 Sudden short circuit test 4.9 Mechanical heat run test:

Chapter5 34 5. Results Chapter6 34 6. Conclusion Chapter7 34 7. Future scope And References

ABOUT THE COMPANY: BHARAT HEAVY ELECTRICALS LIMITED.

Bharat Heavy Electrical Limited (BHEL) is today the largest engineering Enterprise of India with an excellent track record of performance. Its first plant was set up at Bhopal in 1956 under technical collaboration with M/s. AEI, UK followed by three more major plants at Haridwar, Hyderabad and Tiruchirapalli with Russian and Czechoslovak assistance. These plants have been at the core of BHELs efforts to grow and Diversify and become Indias leading engineering company. The company now has 14 manufacturing divisions, 8 service centers and 4 power sector regional centers, besides project sites spread all over India and abroad and also regional operations divisions in various state capitals in India for providing quick service to customers. BHEL manufactures over 180 products and meets the needs of core sectors like power, industry, transmission, transportation (including railways), defense, telecommunications, oil business, etc. Products of BHEL make have established an enviable reputation for high quality and reliability. BHEL has installed equipment for over 62,000 MW of power generation for Utilities, Captive and Industrial users. Supplied 2,00,000 MVA transformer capacity and sustained equipment operating in Transmission & Distribution network up to 400kV AC & DC, Supplied over 25,000 Motors with Drive Control System Power projects. Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants etc., supplied Traction electric and AC/DC Locos to power over 12,000 Km Railway network. Supplied over one million Valves to Power Plants and other Industries. This is due to the emphasis placed all along on designing, engineering and manufacturing to international standards by acquiring and assimilating some of the best technologies in the world from leading companies in USA, Europe and Japan, together with technologies from its-own R & D centers. BHEL has acquired ISO 9000 certification for its operations and has also adopted the concepts of Total Quality Management (TQM). BHEL presently has manufactured Turbo-Generators of ratings up to 560 MW and is

in the process of going up to 660 MW. It has also the capability to take up the manufacture of ratings unto 1000 MW suitable for thermal power generation; gas based and combined cycle power generation as-well-as for 13 diverse industrial applications like Paper, Sugar, Cement, Petrochemical, Fertilizers, Rayon Industries, etc. The Turbo generator is a product of high-class workmanship and quality. Adherence to stringent quality-checks at each stage has helped BHEL to secure prestigious global orders in the recent past from Malaysia, Malta, Cyprus, Oman, Iraq, Bangladesh, Sri Lanka and Saudi Arabia. The successful completion of the various export projects in a record time is a testimony of BHELs performance. Bharat Heavy Electrical Limited (BHEL) is, today, a name to reckon with in the industrial world. It is the largest engineering and manufacturing enterprises of its kind in India and is one of the leading international companies in the power field. BHEL offers over 180 products and provides systems and services to meet the needs of core sections like: power, transmission, industry, transportation, oil & gas, nonconventional energy sources and telecommunication. A wide-spread network of 14 manufacturing divisions, 8 service centers and 4 regional offices besides a large number of project sites spread all over India and abroad, enables BHEL to be close to its customers and cater to their specialized needs with total solutions-efficiently and economically. An ISO 9000 certification has given the company international recognition for its commitment towards quality. With an export presence in more than 50 countries BHEL is truly Indias industrial ambassador to the world.

BHEL HYDERABAD- RAMACHANDRAPURAM UNIT:

SITE: The factory area is about 750 acres out of which the fenced area is about 350 acres
and the rest 400 is left for future expansion of the factory. PRODUCTS OF BHEL HYDERABAD: TURBINES: steam turbines gas turbines TURBO ALTERNATORS steam turbine generators {air cooled type} gas turbine generators {air cooled type}

 COMPRESSORS. SWITCH GEAR. PUMPS. OIL FIELD EQUIPMENT (for oil rigs). PULVERISING MILLS OR BOWL MILLS. HEAT EXCHANGERG. CIRCUIT BREAKERS. SYNCHRONOUS CONDENSERS. The factory consists of the following main shops: 01 SHOP: Gas/steam turbines and compressors shop. It is the largest shop floor n area of 35.311 sq. meters and containing almost 250 machines. 1) STEAMTURBINES: Categories: Utility sets: 60,110,120 MW Industrial sets: 1.5 to60MW. 2) GASTURBINES: Categories: Frame 111(18 MW). Frame V (25. 26 MW). Frame VI (38.4 MW). Frame IX (ll0 MW). 3) COMPRESSORS: Categories (centrifugal compressors only): Horizontal split type. Vertical split type. Barrel type. 02 SHOP: Electrical machines. 1) Turbo alternators: 2 pole and 4 pole generators of capacities ranging from 1.5MWto250MW. 2) Synchronous condensers.

3) Brush less exciter. 4) Boiler feed water pumps. 03 SHOP: Switch gear. 1) Circuit breakers: air blast circuit breakers minimum oil circuit breakers sulphur hexa fluoride circuit breakers 2) Fuel nozzle for gas turbines 3) Delta panel for bowl mills 4) Control panel for electrical machines 5) Plasma coating shrouds for gas turbines 04 SHOP: Ferrous foundry All castings required for plant manufacturing products and castings, bowl mills. 05SHOP: Nonferrous foundry All non ferrous castings required for plant manufacturing products. 06 SHOP: Heat exchangers and fabrication. 1) Heat exchangers: L.P. Heat exchangers 11.P. Heat exchangers Deaerators Kjectors 2) Fabrications: Stator frames Bowl mill shells Foundation frames 07 SHOP: Tool room Jigs and fixtures Single and multi point cutting tools Press tools Backing cone shop. 08 SHOP: Common work shop In heat treatment the following operations are carried out: Hardening, tempering, normalizing, stress reliving, carburizing, nit rising, etc.

Forging (mainly blades). In surface treatment the following operations are carried out: Copper plating, nickel plating, cadmium plant, zinc plating, tin plating, hard chrome plating. Babbling. 09 SHOP: Pattern shop 10 SHOP: Repair shop Up to 110 M\V turbines spare center Area maintenance shop. Rewinding section. Reconditioning section. Refrigeration and air conditioning section. 51 BUILDING: Oil Held equipment. 29 BUILDING: Mechanical testing lab. 70 SHOP: Pumps Boiler feed pumps. Condensate pumps. Oil pumps. Cooling water pumps 90 BUILDING: Instrumental laboratory. SPECIAL FEATURES OF HYDERABAD THE TURBO GENERATORS DESIGNED BY BHEL

High output to weight ratio. Thermo setting class F epoxy insulation both resin rich and micalastic vacuum impregnation. Low loss high-grade silicon steel for laminations. Optimally designed fans on the rotors. Better voltage waveform with less harmonic content. Low wind age loosed and low noise. Static/brushless excitation. Split casing design for low manufacturing cycle for VPI design.

INTRODUCTION OF TURBO GENERATOR

A turbo generator is a turbine directly connected to electrical generator for the generation of electric power. An electrical generator is a machine which converts mechanical energy to electrical energy.

Fig.1.1: Turbo generator outlook.

The following block diagrams shall give us a brief idea about the manufacturing process of a stator, rotor and exciter.

The block diagrams presented above have depicted the standard operating procedure, used for the manufacture of stators, rotors and exciters.

1.2 HISTORY OF TURBO GENERATORS:

Generators are based on the theory of electromagnetic induction, which was discovered by Michael Faraday in 1831, a British Scientist. Faraday discovered that if an electric conductor, like a copper wire, is moved through a magnetic field, electrical current will flow(be induced) in the conductor. So the mechanical energy of the moving wire is converted into the electric energy of the current that flows in the wire.

1.3 PRINCIPLE OF OPERATION:

Turbo generator or A.C. generators or alternators operates on the fundamental Principles of FARADAYS LAWS OF ELECTROMAGNETIC INDUCTION. In them the standard construction consists of armature winding mounted on stationary element called stator and field windings on rotating element called rotor. The stator consists of a cast-iron frame, which supports the armature core, having slots on its inner periphery for housing the armature conductors. The rotor is like a flywheel having alternating north and south poles fixed to its outer rim. The magnetic poles are excited with the help of an exciter mounted on the shaft of alternator itself. Because the field magnets are rotating the current is supplied through two slip rings. As magnetic poles are alternately N and S, they induce an E.M.F and hence current in armature conductors. The frequency of E.M.F depends upon the no. of N and S poles moving past a conductor in 1 second and whose direction is given by Flemings right hand rule.

1.4 SYNCHRONOUS GENERATORS CLASSIFICATION BASED ON THE MEDIUM USED FOR GENERATION:
Turbo generators in Thermal, nuclear, Gas station High speed 3000 rpm Min poles 2 poles Horizontal construction Cylindrical rotor Hydro generators in hydel plants low speed 1000 to 500 rpm more poles 6 or more vertical constructionsalient rotor

1.5 COMPONENTS OF TURBO GENERATOR:

1.5.1 STATOR
Stator Frame Stator Core Stator Windings End Covers

1.5.2 INSULATION 1.5.3 ROTOR

Rotor Shaft Rotor Windings Rotor Retaining Rings Bearings

The following auxiliaries are required for operation: Cooling System Oil Supply System

Excitation System

2.1 STATOR
2.1.1 STATOR FRAME:
The stator frame is of welded steel single piece construction. It supports the laminated core and winding. It has radial and axial ribs having adequate strength and rigidity to minimize core vibrations and suitably designed to ensure efficient cooling. Guide bars are welded or bolted inside the stator frame over which the core is assembled. Footings are provided to support the stator foundation.

Fig: 2.1 stator frame

2.1.2 STATOR CORE:The stator core is stacked from the insulated electrical sheet steel lamination and mounted in supporting rings over the insulated dovetail guide bars. In order to minimize eddy current losses core is made of thin laminations. Each lamination layer is made of individual sections. The ventilation ducts are imposed so as to distribute the gas accurately over the core and in particularly to give adequate support to the teeth. The main features of core are 1. To provide mechanical support. 2. To carry efficiently electric, magnetic flux. 3. To ensure the perfect link between the core and rotor.

Fig: 2.2 stator core

THE PURPOSE OF STATOR CORE To support the stator winding To carry the electromagnetic flux generated by rotor winding. So selection of material for building up of core plays a vital role. The losses in the core are of two types. Hysteresis Loss: Due to the residual magnetism in the core material. Hysteresis loss is given by Wh max 1.6 Eddy Current Loss: Due to the E.M.F induced in the core of the stator. Eddy current loss is given by We max2 f2 t2 In order to reduce the hysteresis loss, silicon alloyed steel, which has low hysteresis constant is used for manufacture of core. The composition of silicon steel is Steel - 95.8% Silicon 4.0% Impurities - 0.2% From the formula it is seen that eddy current loss depends on the thickness of the laminations. Hence to reduce the eddy current loss core is made up of thin laminations which are insulated from each other. The thickness of the laminations is about 0.5mm. The silicon steel sheets are of COLD ROLLED NON-GRAIN ORIENTED (CRANGO) type as it provides the

distribution of flux throughout the laminated sheet.

Fig. 2.3 stator PREPARATION OF LAMINATIONS: For high rating machines each laminations is build of 6 sectors (stampings), each of 60 cut According to the specifications. Press tools are used in the manufacture of laminations. Press tools are mainly of two types. Compounding tools. Blanking and slot notching tools.
LAMINATIONS ARE MANUFACTURED IN TWO DIFFERENT WAYS

COMPOUNDING OPERATION: In this method the stamping with all the core bolt holes, guiding slots and winding slots is manufactured in single operation known as Compounding operation and the press tool used is known as Compounding tool. Compounding tools are used for the machines rated above 40 MW. BLANKING AND NOTCHING OPERATIONS: In case of smaller machines the stampings are manufactured in two operations. In the first operation the core blot holes and guiding slots are only made. This operation is known as Blanking and the tools used are known as Blanking tools. In the second operation the winding slots are punched using another tool known as Notching tool and the operation is called Notching.

THE DIFFERENT OPERATIONS IN MANUFACTURE OF LAMINATIOS: Debugging operation: In this operation the burrs in the sheet due to punching are debugged. There are chances of short circuit within the laminations if the burrs are not removed. The permissible is about 5 micrometer. For debugging punched sheets are passed under rollers to remove the sharp burs of edges. Varnishing: Then depending on the temperature withstand ability of the machine the laminations are coated by varnish which acts as insulation. The lamination sheets are passed through conveyor, which has an arrangement to sprinkle the varnish is obtained. The sheets are dried by a series of heaters at a temperature of around 260-350 C. Two coatings of varnish are provided in the above manner till 12-18mm thickness of coat is obtained.
The prepared laminations are subjected to following tests:

Xylol test - To measure the chemical resistance. Mandrel test - When wound around mandrel there should not be any cracks. Hardness test - Minimum 7H pencil hardness. IR value test - For 20 layers of laminations insulation. ASSEMBLY OF CORE: The stator laminations are assembled as separate cage without stator frame. The entire core length is made in the form of packets separated by radial ducts to provide ventilating passages for the uniform cooling of the core. The thickness of each lamination is 0.5mm and the thickness of lamination separating the packets is about 1mm. The lamination separating each packet has strips of nonmagnetic material that are welded to provide radial ducts. The segments are staggered from layer to layer so that a core of high mechanical strength and uniform permeability to magnetic flux is obtained. Stacking mandrels and bolts are inserted into the windings slot bores during stacking provide smooth slot walls.

Fig: 2.4 assembling of core

To obtain the maximum compression and eliminate under setting during operation, the laminations are hydraulically compressed and heated during the stacking procedure when certain heights of stacks are reached. The complete stack is kept under pressure and located in frame by means of clamping bolts and pressure plates. The clamping bolts running through the core are made of nonmagnetic steel and are insulated from the core and pressure plates to prevent them from short circuiting the laminations and allowing the flow of eddy currents. The pressure is transmitted from the clamping plates to the core by clamping fingers. The

clamping fingers extend up to the ends of the teeth thus, ensuring a firm compression in the area teeth.

Fig: 2.5assembled core

The core building or assembling method depends on the insulation system used. 1. For resin rich insulation system the laminations are stacked in the frame itself. 2. For resin poor insulation system (VPI) cage core of open core design is employed.

2.1.3 STATOR WINDINGS:

Stator winding is the one which induces EMF and supplies the load. Stator winding is placed in the slots of stator core. Due to the advantages of generation and utilization of 3 phase power we use three phase windings for generation. So number of slots must be a multiple of 3 (or 6 if two parallel circuits are required). Generally two layer lap winding, chorded to about 5/6 pitch which practically eliminates 5 and 7th harmonics from the flux wage or open circuit induced EMF wave is used. The stator coil is made up of number of strips instead of single solid piece to reduce the skin effect. Copper material is used to make the coils. This is because i. Copper has high electrical conductivity with excellent mechanical properties. ii. Immunity from oxidation and corrosion. iii. It is highly malleable and ductile metal. There are two types of coils manufactured in BHEL, Hyderabad. Diamond pulled multi turn coil (full coiled): Roebel bar (half coiled). Generally diamond pulled multi turn coils are used for low capacity machine. In this coils are pulled in a particular shape similar as diamond thats why they are called so. In large capacity machines we use ROEBEL bars. These coils were constructed after considering the skin effect losses. In the straight slot portion, the conductors or strips are transposed by 360 degrees. The transposition is done to ensure that all the strips occupy equal length under similar conditions of the flux. High purity (99%) copper conductors/strips are used to make the coils. This results in high strength properties at higher temperatures so that deformations due to the thermal stresses are eliminated. The high voltage insulation is provided according to the resin poor mica base of thermosetting epoxy system. Several half overlapped continuous layers of resin poor mica tape are applied over the bars. The thickness of the tape depends on the machine voltage.
th

Fig: 2.6 stator windings

Slot Discharges: Slot discharges occur if there are gaps within the slot between the surface of the insulation and that of the core. This may cause ionization of he air in the gap, due to breakdown of the air at the instances of voltage distribution between the copper conductor and the iron. Within the slots, the outer surface of the conductor insulation is at earth potential, in the overhanging it will approach more nearly to the potential of the enclosed copper. Surface discharge will take place if the potential gradient at the transition from slot to overhang is excessive, and it is usually necessary to introduce voltage grading by means of a semiconducting (graphite) surface layer, extending a short distance outward from the slot ends.

MANUFACTURE OF STATOR COILS:

Various operations carried out during manufacture of stator coil are 1. Set the straightening and cutting machine using guide pilot. 2. Cut the conductor strips as per the requirement. 3. Set the press for Roebel Transposition. 4. Assemble strips with respect to template and transpose. 5. Assemble both halves of coil sides to from I. One Roebel half bar II. Insert insulation of halves between quarter bars matching the straight part zone as per drawing. 6. Cure half coil on hydraulic press. This process is known as Baking. (a) Remove insulation at the ends of the strips. (b) Test for inter-strip and inter-halves shorts. 7. Set the universal former as per standards. Check the setting of universal former for (a)Length of straight part also mark diagonals/former walls inside for cross check. (b)Check for marking made by template. 8. (a) Place the bar on former. (b) Form the overhang bends as per standards.

(c) Remove clamps and inserts overhand insulation to both roebel halves with an application of araldite mixture. (d) The bar is allowed to cure by giving supply to heating clamps. 9. Remove heating clamps and take out the bar halves from former. (b)Round off sharp edges of straight part and dress up overhang halves insulation of both halves without damage to copper strip insulation and to copper stacks. PROCESS OF TAPING: 1. Tape the bar with Resin poor fine mica paper tape on straight part of bar taking copper foil outside the tape. 2. Tape with one layer of conductive polyester fleece tape. a) Provide main insulation b) OCP protection tape 3. Tape the straight part of bar with conductive polyester fleece tape with starting and ending shall be on straight part of bar. 4. Tape with mica splitting tape with accelerator taking Ocp layer into and leaving. 5. Tape the straight part of bar with polyester Conductive fleece tape. 6. Provide End Corona protection taping. 7. Provide overhang with protective tape (Polyester glass tape) 8. Test for inter-strip shorts.

Fig: 2.7 mica taping machine.

STATOR END COVERS: The stator end covers are attached to end flanges of stator frame and also rest on the foundation plate. The end covers are made up of non-magnetic material (Aluminum castings) to reduce stray load and eddy current losses. PHASE CONNECTORS: The phase connectors consist of flat copper sections, which results in low specific current loading. The phase connectors are wrapped with resin rich mica tape. After curing the connectors are attached to the pressure plate with clamps and bolts. RESISTANCE TEMPERATURE DETECTORS: The temperature measurements on the generator are made with RTDs. They are placed at various sections of the core and winding. When making measurements with RTDs the resistance element is exposed to the temperature to be measured. The RTD works on the principle of the change in electrical resistance of a conductor due to temperature. R= Ro (1+ T); Where Ro = reference resistance at room temperature; R= temperature coefficient of resistance; T = temperature difference in C.

ASSEMBLY OF WINDINGS
WINDING HOLDER ASSEMBLY: Assemble the winding holder as per the drawing requirement and check all the winding hold with template with respect to core. ASSEMBLY OF HG RINGS: Assemble the HG rings on the both the side, turbine side as well as laminated side. Pass HGL gauge in all the slots to detect laminations projection of the bottom surface if any lamination projection are noticed then rectify the projection. Check prior operation completion. IDENTIFICATION OF RTD SLOTS: Identify all the RTD slots with respect to the drawing and assemble the RTD slots as per the drawing purposes required. Identify all the slots with slots number as per the drawing. BOTTOM BARS LAYING: Pressing of bottom bars: Each individual bars subjected for pressing at 60 kg/cm2 horizontal & vertical in order to obtain predetermine the dimensions up to 30 minutes. This process is carried out for all the bottom bars before lying to the respective slots. By following above procedure first bar is laid in to the respective slots when the bar is center to the core centre by measuring pitch dimensions on both sides. Similarly next bar is laid in to the respective bar by following procedure. After laying the every two bars the over hangs are reinforced with glass mat at three different locations on both sides and tying the bars with neoprene glass view. Similarly the above procedure is following for all the eliminating bars. After completion bottom bars laying the bars reinforced end wedges and middle wedges. Then the bottom bars are subjected to D.C high voltage. Inter layer inserts & RTDS assembles: All the inter layer inserts & RTDS are assembled as per drawing required i.e. inter layer inserts are assembled in each and every slots except RTDS slots. In RTDS slots only RTDS are assembled before laying top bars. Stiffener assembles: Stiffener are assembled on the winding layers on to the bottom bars by reinforcing & placing glass mat and tying with neipring glass. Stiffeners are carried out on the both sides. TOP BARS LAYING: Pressing of top bars: Each individual top bar is subjected to pressure 60kg/cm2 horizontally and vertically for duration of 30minutes in order to obtain pre determine dimensions. The above operation for each top bar before laying in to their respective slots. First top bar laying is carried out by centering the bar with respect to the stator core & check the pitch dimensions on both sides.

Similarly the next bar is assembled in to respective slots by following the above procedure. After laying every two bars the over hangs are reinforced by inserting glass mat at 3 different locations on the both sides. By following the above procedure all the top bars are layed in to the slots by full filling the drawing requirements then the top bars are reinforced wedging with HGW over layer and placing glass mat under the wedges. All the respective wedges are driven by matching with respective ventilation holes of the pores. Similarly all the wedges are driven in all respective slots by blocking the top bars. After completion top bars laying top bars are subjected to D.C. high voltage.

Connecting rings assembly: All connecting rings assemble as per the drawing requirements, and then the phase groups are processed by jointing, bracing and insulation. After completion of jointing bracing and insulation once again it is subjected to D.C. high voltage. Termination of desired RTDS on one side for monitoring the post curing temperature.

2.2 Insulation
2.2.1 Insulation systems
BHEL INSULATION SYSTEM FOR TURBO GENERATORS: BHEL had Bitumen insulation system for low & medium rating TGS and switched over to resin rich Thermo setting type as a step towards increasing reliability and upgrading technology. Micalastic system has been adopted for high rating machinery. BITUMEN SYSTEM & LIFE EXTENSION: The experience with Bitumen system has been generally satisfactory & practically negligible service failure has been reported on these sets. Mechanical damage most commonly associated with this system i.e., tape separation, due to thermal expansion of the winding during normal or abnormal temperature eyeing is not met any of sets. Though outage due to insulation failures has been considerably low, yet these machinery would need to be attended to have life extension above their estimated life of 25 years. Major inspection of the machine condition is by checking the healthiness of windings & life of bar insulation. Rehabilitation, if needed, requires restoration of varnish, removal of bitumen & cleaning, tightening of fasteners/supports, modification of bus bars, use of new wedges & other winding components. The replacements are required because of vibration / external damage etc. VARIOUS INSULATION SYSTEMS & PRACTICES: Large & medium range motors are provided with following insulation system. 1. Resin flux Insulation System: This system is used on earlier designs & where duplicate or spare motors to suit the customer requirements are required. In the coming years this system may become absolute.

2. Resin Rich micalastic Insulation System: The system provides use of Resin rich

polyester backed epoxy micafolium on straight portion & resin rich polyester backed epoxy mica paper tape on overhang with a final layer of polyester shrink tape. The system is highly productive during coil manufacture and housing. 3. Resin poor Micalastic Insulation System: Resin poor micalastic system is adopted for large range Ac Induction and synchronous machines. These are designated to meet specific customer requirement hence for unique in nature to each other. The main insulation consists of resin poor epoxy mica paper tape all over the oil periphery with varying number of layers on straight and overhang portions. RESIN POOR RESIN RICH 1. Epoxy resin content is about 8%. 2. This method follows Thermo Setting Process. 3. There is a need for addition of resin from outside. 4. Time required for this cycle is less. 5. Repairing is very difficult. 6. Overall cost is less compared to resin rich. 1. Epoxy resin content is about 40%. 2. This method also follows Thermo Setting Process. 3. Further addition of resin is not required from outside. 4. its a very long process and time consuming. 5. Repairing is easy. 6. Overall cost is more.

2.2.2 VACUUM PRESSURE IMPREGNATION

INTRODUCTION TO VPI SYSTEM: DR. MEYER brought the VPI system with the collaboration of WESTING HOUSE in the year 1956. Vacuum Pressure Impregnation has been used for many years as a basic process for thorough filling of all interstices in insulated components, especially high voltage stator coils and bars. VPI is a process, which is a step above the conventional vacuum system. VPI includes pressure in addition to vacuum, thus assuring good penetration of the varnish in the coil. The result is improved mechanical strength and electrical properties. With the improved penetration, a void free coil is achieved as well as giving greater mechanical strength. With the superior varnish distribution, the temperature gradient is also reduced. In order to minimize the overall cost of the machine & to reduce the time cycle of the insulation system vacuum pressure Impregnated System is used. The stator coils are taped with porous resin poor mica tapes before inserting in the slots of cage stator, subsequently wounded stator is subjected to VPI process, in which first the stator is vacuum dried and then impregnated in resin bath under pressure of Nitrogen gas.

Fig: 2.8 VPI systems

Features and Benefits: State-of-the-art process for completely penetrating air pockets in winding insulation. Increases voltage breakdown level. (Even under water!) Proven submergence duty system Improved heat transfer- windings are cooler, efficiency is improved. Improves resistance to moisture and chemicals. Increases mechanical resistance to winding surges.

Vacuum Pressure Impregnation of resin poor insulated jobs:

Variant01
Preheating 60 5 C for 3hrs 0.4mbar

Variant-02
60 5 C for 12hrs

Variant-03
60 3 C for 12hrs

Any other information

Vacuum to be maintained

0.2mbar/0.4mbar

<0.2mbar (both together shall not exceed 50hrs including rising time) Stopping vacuum pumps for 10min shall check 17hrs Vacuum drop. The vacuum drop shall not exceed by 0.06mbar for 10min 80min 4bar 3hrs

Vacuum heating time

3hrs

0.2mbar for 9hrs 0.4mbar for 17hrs

Increase in pressure Maximum pressure Pressure holding Post curing

40min 3bar 3hrs

80min 4bar 3hrs

At140 5 C for 14hrs

At140 5 C for 32hrs

At140 5 C for 32hrs

2.2.3 PROCESS:
General: The jobs that are entering tank for Vacuum Pressurized Impregnation shall not have any oil based coatings. Any such, rust preventive/ corrosion preventive viz., red oxide etc., shall be eliminated into the tank.
Resin

in the storage tank shall be stored at 10 to 12 C and measured for its viscosity, viscosity rise. Proper functioning of the impregnation plant and curing oven are to be checked by production and cleared for taking up of job for impregnation Preheating: The job is to be loaded in the curing oven and heated. The temperature is to be monitored by the RTD elements placed on the job and the readings are logged by production. The time of entry into the oven, time of taking out and the temperature maintained are to be noted. Depending on convenience of production the jobs can be preheated in impregnation tank by placing them in tubs. The impregnation tubs used for impregnation of jobs are to be heated in the impregnated tank itself, when the jobs are preheated in the curing oven. Impregnation: Job insertion into preheated tub and insertion into tank by the time, the preheating of job is completed, it is to be planned in such a way that the heating of tub and tank heating matches with the job. This is applicable when the job is heated in the curing oven separately. The preheated job is to be transferred into the tub by crane handling the job safely and carefully without damage to the green hot insulation.

Insertion of tub with job into the impregnation tank

Fig: 2.9 VPI Resin tub

The warm tub with job is inserted into impregnation tank by sliding on railing, in case of horizontal tank. The thermometer elements are to be placed at different places on the job. The connection for inlet resin is to be made for collection of resin into tub. After ensuring all these lid of the impregnation tank is closed. In case of vertical tank the job along with tub is slinged and inserted carefully into impregnation tank without damage to insulation.

Drying the job in vacuum

The job is to be dried under vacuum. Drain out the condensed moisture/ water at the exhausts of vacuum pumps for efficient and fast vacuum creation. Also check for oil replacement at pumps in case of delay in achieving desired vacuum. Heating the resin in the storage tank The completion of operations of drying and the heating of the resin in the storage tank are to be synchronized. The heating of resin in the tank and pipeline is to be maintained as at preheating temperature.

Admission of resin into impregnation tank

The resin is allowed into the impregnation tank tub if required from various storage tanks one after the other up to a level of 100mm above the job generally, after which the resin admission is stopped. After 10mins of resin settling the tank is to be pressurized by nitrogen. While admitting resin from storage tanks pressurize to minimum so that nitrogen will not affect resin to spill over in tank.

Pressurizing/gelling Withdrawal of resin from impregnation tank to storage tank

The pressure cycle is to be maintained.

The resin that is pressurized as per pressure cycle by which the opening of relevant valves will allow the resin to come back to the storage tank. The job also shall be allowed for dripping of residue of resin for about 10min. After dripping, withdrawal of resin in various storage tanks is to be carried out.

Taking out the tub with job from impregnation tank

The lid is then opened after taking precautions of wearing mask and gloves for the operating personnel as a protection from fumes. The job is withdrawn from impregnation tank by sliding on railing for horizontal and slinging on to crane for vertical impregnation tanks. Post curing: The job is post heated. The time for raising from job temperature to this temperature as per relevant annexure. The time at which the heating is started, achieved and maintained is to be logged. Electrical testing: All jobs that are impregnated till above process are to be tested for electrical tests. After ensuring that all the temperature/vacuum conditions stipulated for drying, impregnation and curing operations have been properly followed, the job is to be released for this operation.

2.3 ROTOR
Rotor is the rotating part of alternator. It is used to support field winding placed in slots on the rotor. FOR 2-POLE GENERATOR: Solid rotors are manufactured from forged alloy steel with suitable alloying elements to achieve very high mechanical and superior magnetic properties. This type of rotor can withstand even up to speed of 3000 rpm. Rectangular or trapezoidal rotor slots are accurately machined to close tolerances on slot milling machine. For indirectly cooled generator rotors, ventilation slots are machined in the teeth.

FOR 4-POLE GENERATOR: For directly cooled rotors, sub slots are provided for cooling Generator rotors of 1500 RPM are of round laminated construction. In this case rotor is made up of two parts (1) core, (2) lamination. The outer diameter of core and the inner diameter of laminations are equal. So for inserting the core inside the laminations the laminations are first red heated at medium temperature for 15 hours in BELL FURNACE. After that the core is shrunk fitted inside the laminations. Thus punched and varnished laminations of high tensile steel are mounted over machined shaft and are firmly clamped by end clamping plates.

Fig: 2.10 rotor body.

2.3.1ROTOR SHAFT :
Rotor shaft is a single piece solid forming manufactured from a vacuum casting. It is forged from a vacuum cast steel ingot. Slots for insertion or the field winding are milled into rotor body. The longitudinal slots are distributed over the circumference such that two solid poles are obtained. To ensure that only a high quality product is obtained, strength tests, material analysis and ultrasonic tests are performed during the manufacture of rotor. The high mechanical stresses resulting from the centrifugal forces and short circuit torques call for a high quality heat treated steel. After completion, the rotor is balanced in various planes at different speeds and then subjected to an over speed test at 120% of the rated speed for two minutes.

Fig: 2.11 rotor shaft.

Approximately 60% of rotor body circumference has longitudinal slots which hold the field winding. Slot pitch is selected so that the two solid poles are displaced by 180 degrees. The rotor wedges act as damper winding within the range of winding slots. The rotor teeth at the

ends of rotor body are provided with axial and radial holes enabling the cooling air to be discharged into the air gap after intensive cooling of end windings.

2.3.2 ROTOR WINDINGS:

The rotor windings consist of several coils inserted into the slots and series connected such that two coil groups form one pole. Each coil consists of several series connected turns, each of which consists of two half turns connected by brazing in the end section. Thickness of each strip can be made up to 10.5 mm but here in BHEL we make only up to 5.3 mm. The rotor bearing is made of silver bearing copper ensuring an increased thermal stability. For ventilation purpose the slots are provided on the coil and on inter strip insulation layer both. The individual turns of coils are insulated against each other by interlayer insulation. Lshaped strips of laminated epoxy glass fiber fabric with nomex filter are used for slot insulation.

Fig: 2.12 rotor winding.

The slot wedges are made of high electrical conductivity material and thus act as damper windings. At their ends the slot wedges are short circuited through the rotor body. The inter space between the overhang is called slot through.

CONSTRUCTION
The field winding consists of several series connected coils inserted into the longitudinal slots of rotor body. The coils are wound so that two poles are obtained. The solid conductors have a rectangular cross section and are provided with axial slots for radial discharge or cooling air. All conductors have identical copper and cooling duct cross section. The individual bars are bent to obtain half turns. After insertion into the rotor slots, these turns are brazed to obtain full turns. The series connected turns of one slot constitute one coil. The individual coils of rotor are connected in a way that north and south poles are obtained.

CONDUCTOR MATERIAL:
The conductors are made of copper with a silver content of approximately 0.1%. As compared to electrolytic copper, silver alloyed copper features high strength properties at high temperatures so that coil deformations due to thermal stresses are eliminated.

INSULATION
The insulation between the individual turns is made of layer of glass fiber laminate. The coils are insulated from the rotor body with L-shaped strips of glass fiber laminate with nomex interlines. To obtain the required leakage paths between the coil and the rotor body thick top strips of glass fiber laminate are inserted below top wedges. The top strips are provided with axial slots

of the same cross section and spacing as used on the rotor winding. Insulation b/w overhang is done by blocks made of HGL.

ROTOR SLOT WEDGES

To protect the winding against the effects of centrifugal forces, the winding is secured in the slots with wedges. The slot wedges are made of copper alloy featuring high strength and good electrical conductivity. They are also used as damper winding bars. The slot wedges extend beyond the shrink seats of retaining rings. The wedge and retaining rings act on the damper winding in the event of abnormal operations. The rings act as short circuit rings in the damper windings.

END WINDING BRACING

The spaces between the individual coils in the end winding are filled with insulated members that prevent coil movement. Two insulation plates held by HGL high glass laminate plates separate the different cooling zones in the overhangs on either sides.

2.3.3 ROTOR RETAINING RINGS:

The centrifugal forces of the rotor end winding are contained by single piece rotor retaining rings. Retaining rings are made of non-magnetic high strength steel in order to reduce stray losses. Each retaining ring with its shrink fitted. Insert ring is shrunk on to the rotor body in an overhang position. The retaining ring is secured in the axial position by snap rings.

Fig: 2.13 rotor retaining rings

The rotor retaining rings withstand the centrifugal forces due to end windings. One end of each ring is shrunk fitted on the rotor body while the other end overhangs the end windings without contact on the rotor shaft. This ensures an unobstructed shaft deflection at the end winding.

2.3..4 ROTOR FANS

The cooling air in generator is circulated by two axial flow fans located on the rotor shaft one at each end. To augment the cooling of the rotor winding, the pressure established by the fan works in conjunction with the air expelled from the discharge parts along the rotor. The blades of the fan have threaded roots for being screwed into the rotor shaft. The blades are drop forged from an aluminum alloy. Threaded root fastenings permit angle to be changed. Each blade is secured at its root with a threaded pin.

Fig: 2.14 rotor fan

2.3.5 BEARINGS
GENERATOR BEARINGS: The turbo generators are provided with high pressure
lubricated belt aligning elliptical type bearings to ensure high mechanical stability and reduce vibrations in operation. The bearings are either shield mounted or pedestal mounted type. Continuous oil supply is maintained in the bearings for continuous cooling and also for lubrication purpose. This continuous oil supply of the bearings is obtained from the turbine oil system. The temperature of each bearing is monitored with two RTDs embedded in the lower bearing sieves so that the measuring point is located directly below the babbits. The rotor shaft is sleeve bearing having post oil lubrication. The bearings are located in bearing pedestals. The oil required for bearing lubrication and cooling is obtained from the turbine oil supply system and supplied to lubricating gap via the bore in the bearing pedestals and via grooves in the lower half bearing shell. The lower bearing shell with its self aligning outer portion rests on the bearing pedestal. The ES bearing pedestal is insulated to prevent the flow of the shaft currents and to provide for the insulation of generator bearing from the ground. The pipe fingers to the bearing pedestals are likewise insulated from the bearing housing. A tangential stop is provided at the bearing shell parting plane to prevent the bearing shell from turning in the pedestal. The inner surface of the cast bearing sleeve body is provided with spiral dove till grooves, which firmly hold the babbits, linear to the bearing sleeve body. The lower bearing sleeve has grooves to admit the tube oil into the bearing surface. The upper sleeve consists of wide overflow groove through which the oil is distributed over the shaft journals and fed to the lubricating gap. The oils is drained laterally from the lubricating gap, caught by the baffles, collected in the bearing and returned to the tube oil tank. All the generator bearings are provided with a shaft lift oil system to reduce bearing friction during startup and turning gear operation. High pressure oil is forced between the bearing surface and the shaft journals, lifting the rotor to allow the formation of lubricating oil film. The bearing temperature is monitored with thermocouples located approximately in the plane of maximum oil film pressure. The RTDs screwed in the position on one side of the lower bearing sleeve from outside the detector extending up to the Babbitt liner.

Fig: 2.15 rotor fan

BEARING INSULATION: To prevent damage to the journals due to shaft currents, bearing and oil piping on either side are insulated from the foundation frame, for facilitating and monitoring of healthiness of bearing insulation, split insulation is provided. LUBRICATION SYSTEM: The bearing lubrication is done by circulating oil under pressure and complete system forms part of the main tube oil system of the turbine. SKEWING: Sometimes slots are skewed to minimize the effect of voltages and resulting from the ripple in the air gap flux produced by the stator slots. Skewing is slot is essentially a full slot pitch in the length of the core will eliminate voltages due to slot ripple. The effect of the number of slots which produces undesirable ripple voltage can be limited by some degree of skew. SCANVENGING: When Hydrogen is removed from the machine to allow inspection on services, the scavenging process must be safe from explosion hazard. This usual method is to admit Carbon dioxide and exhaust Hydrogen from the highest point of the enclosure with the machine de energized and either at stand still or on the turning gear for filling the Hydrogen, the gas flows are reversed.

3.1 VENTILATION
Turbo generators are designed with the following ventilation systems: Closed circuit air cooling with water or air coolers mounted in the pit. Closed circuit hydrogen cooling with water or hydrogen coolers mounted axially on the stator frame. The fan design usually consists of two axial fans on either made of cast aluminum with integral fan blades or forged and machined aluminum alloy blades screwed to the rotor. In case of 1500 RPM generators, fabricated radial fans are provided.

Different types of Ventilation system are:

1. Radial Ventilation system. 2. Axial Ventilation system. 3. Multiple inlet Ventilation system. RADIAL VENTILATION SYSTEM: It is commonly employed because the movements of the rotor induce natural centerful movements of the air as required by the rotor fans. a) Fig 1. shows a typical method suitable for small machine. The end brackets are shaped to guide air over the over changing and the back of the core. Baffles are fitted to improve the fan efficiency. For large machines sub-division of the core is necessary. b) The air paths through the radial ducts are in parallel with those across the overhang converters. A high rate heat dissipation is possible in the gap between smooth bore rotors and stators, unless this gap is very short on account of very high air speeds accompanied by turbulence. AXIAL VENTILATION: It is suitable for machines of moderate output and high speed. To avoid undue centrifugal forces it is necessary to have solid rotor and a restricted spider. These make it difficult to provide adequate air paths to radial ventilating ducts. Further the tendency in design is to increase core lengths and restricts core diameters in order to reduce the cost of the machine. Fig shows a method of applying axial ventilation to a small machine with plain cores. To increase the cooling surface holes may be punched in core plates, to form through ducts, where considerable heat dissipation occurs. This greatly improves the cooling but requires a large core diameter, for the increased core depth necessary.

COMBINES RADIAL & AXIAL VENTILATION: This method is first developed for small turbo alternators and later employed for large motors. Fig 3 shows the arrangement of an induction motor for fixed ventilation. The air is drawn at one end, and encouraged to pass through the ducts by baffling the fan end of the rotor spider. The rotor mounted fan ejects the air.

MULTIPLE INLET VENTILATION: With great lengths of core there is tendency to starve the central radial ducts of air. With the multiple inlet system it is possible to build machine with long cores and obtain an efficient centre cooling. The stator frame is divided into separate air circuits fed in parallel.The cooling of totally enclosed machines present a special problem inside the machine, it can have no air connection with the outside. The methods of fan cooling are shown in Fig 4. At (a) a shaft mounted fan external to working parts of the machine blows the air over the carcasses through a space between the main housing and a thin cover plate. An internal fan produces internal air circulation; this avoids temperature gradient across the air gap. At (b) an internal fan circulates the heat to the carcasses. Air is also blown over the outside of the carcasses to improve the dissipation. FORCED VENTILATION: This is used for the largest machines and hence of immediate interest, which requires many tons of cooling air per hour, and permits the cleaning of the air by suitable filters. Avoiding the clogging of the ducts which may otherwise with such large volumes of air on high speed machines rotor mounted fans may be sufficient. The air is filter or washed through a water spray then baffled against flooded scrubbing surfaces to precipitate dirt. It is then dried by passing over a series of dry scrubbing plates. A more complete means of securing clean cooling air is the closed circuit system as employed for turbo alternators. The hot air from the machine is passed through a water cooled refrigerator then returned to the machine by a centrifugal fan. Though in some systems coolant flows in axial direction from one end of the machine to the other end, it appears that a radial system has certain advantages and a combination of the radial and axial cooling proves to be more efficient than any other system. Different experiments were conducted and the following conclusions were drawn: 1) With a ventilation system, the influence of the rotation upon the total volume of the air is nearly negligible. 2) On the discharge side, the axial distribution of volumes in the vent ducts is made somewhat more uniform by the influence of rotation. The influence is less when the air gap is larger and for the air gaps usually employed, the effect of rotation upon axial distributions quite small to the intake side, undoubtedly there is like wise modification in the axial volume distribution due to rotation, but now from theoretical consideration there are probably

differences between maximum vent and minimum vent duct velocities than at standstill. But the change is doubtlessly quite small with the usual size of air gap. In the large machines, the coils are sunk so that there is an axial passage above them in which the flow is not disturbed appreciably by rotation.

COOLING OF ROTOR WINDING: Each turn is subdivided into four parallel cooling zones. One cooling zone includes the slot from the center to the end of the rotor body while another covers half end winding to the end of the rotor body. The cooling air for the slot portion is admitted into the slot bottom ducts below the rotor windings. The hot gas at the rotor winding of the rotor body is then discharged into the air gap between the rotor body and the stator body through the radial opening in the conductors and in the rotor wedges. The cooling air from the end winding is drawn from below the rotor retaining rings. It rises radially along the individual coils and is then discharge into the air gap via axial radial slots in the end portions of the rotor teeth. The overhead cooling is divided into 4 zones, two for the poles and two for the winding portions. Hence this type of rotor is called 4- type. ROTOR FANS: Two axial flow fans located on the rotor shaft one on either end circulate the generator cooling air. To augment the cooling of the rotor winding the presence established by the fans works in conjunction with the air expelled from the discharge ports along the rotor. The blades of the fans have threaded roots for being screwed unto the rotor shaft. The blades are drop forged from an aluminum alloy. Threaded roots fastening permits the blade angle to be changed. Each blade is screwed at its root with the threaded pin. SLIP RINGS: Slip rings are provided for turbo generators with conventional rotating or static excitations system. These are of alloy steel forgings shrunk fitted on the rotor shaft and are insulated from the shaft. Helical grooves are machined on the surface of the slip rings for efficient cooling. For rotor earth fault protection, the rotor is provided with an additional brush, which is fixed to the bearing on the drive side and is in contact with the rotor shaft during operation. Rotor is dynamically balanced to eliminate unbalance and vibrations in operation.

3.2 COOLING
Indirect Cooling: Definition: Indirectly cooled machines dissipate their losses to a cooling medium, which is entirely outside the coil insulation. All air-cooled machines, with rare exceptions, are cooled in the manner, as well as most hydrogen-cooled machines under 100mm VA. Turbogenerators rated above 100mVA usually employ direct cooling. Cooling Media: Air is the most commonly used medium. Hydrogen provides better heat transfer with much less wind age loss, which is nearly proportional to density. Frequently hydrogen is used at higher than atmospheric pressure, which further improves its heat transfer capabilities but with greater wind age loss. Other advantages of hydrogen are the reduction of insulation oxidation and fire hazards. Direct Cooling: Definition: Direct cooling is the process of dissipating the armature and field coil losses to a cooling medium within the main conductor insulation wall. Machines cooled in this manner are also called as super charges or inner cooled by various manufacturers. The cooling medium is in either direct contact with the conductor copper or is separated only by thin materials having little thermal resistance. Direct cooling eliminates the temperature differential resulting from heat flow through the coil insulation, providing greater currentcarrying capability for the same hot-spot temperature rise. Cooling Media: Hydrogen, water and oil are normally used. Most directly cooled turbine generators operate in a hydrogen atmosphere, which provides cooling for all the machines except, in some instances, the armature coils. These may be cooled from the common hydrogen stream or by a separate oil, water or high-pressure hydrogen steam. Because of the limited cross section available within the coils for cooling medium flow the temperature raise of the cooling medium in absorbing the heat loss is usually the most important factor determining the hotspot temperature raise. Direct water-cooling of the rotor windings of very large turbine generators are also employed. Direct cooling is also applied to salient pole synchronous capacitors and hydro generators of the largest rating. The direct cooling medium is usually water. Electrical insulation with hydrogen direct cooling must also allow for adequate creep age distances at the coil hydrogen inlets and outlets. Oil and hydrogen system require in addition, insulated piping. Water is de ionized to maintain electrical conductivity. In rotating machinery the heat is dissipated principally by convention. For small machines, either by natural cooling or by a fan mounted on the shaft, heat can be dissipated. For bigger machines the core masses becomes too large to be adequately cooled by either outer surface. Radial and

axial ducts must be used together with proper means of supplying cooling air to the new surface exposed. As one of the most difficult case, the turbo generator with its exceptionally massive core requires a highly elaborate gaze duct cooling system, in order that all parts of the core may be kept at temperatures within the limits imposed by the insulation. COOLERS: Most large machines have closed circulating systems with fin-tube coolers to transfer the heat absorbed by the gas to the cooling water. For hydrogen cooled machines the coolers usually consists of several units ranged either vertically or horizontally within the stator frame. For air cooled machines the closed re circulating system provides clean, cooled air dependant on the environment. Horizontal air cooled machines have a single cooler located in a horizontal position below the machine and vertical water wheel generators usually have several coolers distributed around the outer periphery of the stator within the air housing.

3.3 EXCITATION SYSTEM

The basic use of given exciter system is to produce necessary DC for turbo generator system. Principal behind this is that PMG is mounted on the common shaft which generates electricity and that is fed to yoke of main exciter. This exciter generates electricity and this is of AC in nature. This AC is that converted into DC and is that fed to turbo generator via C/C bolt. For rectifying purpose we have RC block and diode circuit. The most beautiful feature is of this type of exciter is that is automatically divides the magnitude of current to be circulated in rotor circuit. This happens with the help of AVR regulator which means automatic voltage regulator. A feedback path is given to this system which compares theoretical value to predetermine and then it sends the current to rotor as per requirement.

Fig: BLE exciter

The brushless exciter mainly consists of:1. Rectifier wheels 2. Three phase main exciter 3. Three phase pilot exciter 4. Metering and supervisory equipment. The brushes exciter is an AC exciter with rotating armature and stationery field. The armature is connected to rotating rectifier bridges for rectifying AC voltage induced to armature to DC voltage. The pilot exciter is a PMG (permanent magnet generator). The PMG is also an AC machine with stationery armature and rotating field. When the generator rotates at the rated speed, the PMG generates 220 V at 50 hertz to provide power supply to automatic voltage regulator.

3.4 ASSEMBLY

\
The following fig shows overall view of air cooled turbo generator.After impregnation

process,the mechanical strengths and mechanical supports have to be examined as required for balancing the generator.Then the stator is kept on bottom frame. By using pilot wire inner diameter of stator body is measured to balance the stator in whole casing.The rotor is inserted on bearing.The bearing made of white metal,which greatly increases its cost.Bearing provides support and grease reduces friction .Scraper sheet consists of both brass and bronze.It retains grease inside the bearing and prevents it from spilling out.The bearing is placed on the pedestal.The gap between rotor and stator is about 17mm.Oil is circulated through the bearing at every time at a pressue of 80kg/cm sq.The oil lifts the rotor by a very a small amount and thus helps frictionless rotation of rotor inside the stator.The outer covering of the machine is made up of mild steel.then top cover is placed. Exciter tests are carried out at the bearings as it withstandsthe rotor shaft at synchronous speed .the test are high voltage test and vibration test in three modes-axial,horizontal and vertical.the vibration limi is about 5 microns.

then the final testing is carried out.rotor is tested at ten times the rated voltage and stator is tested at (2n+10)kv where n is the rated voltage in kv.

FEATURES OF AIR COOLED TURBO GENERATORS. *High output to weight ratio. *Thermo-setting class-F epoxy insulation.Both resin-rich and micalastic Global impregnation system *Low loss high-grade silicon steel for lamination,optimally designed fans on rotor for effective air flow *Better voltage waveform with lesser harmonics content *Low windage loss and low noise *Static/brushless excitation *Split casing design for a lower manufacturing-cycle for VPI design,etc.

IMPORTANT DIMENSIONS&WEIGHTS:*Heaviest lift of generator stator:255 Tons *Rotor weight:68 Tons *overall statordimensions[L*B*H]:8.83M*4.1M*4.02M *Roter dimensions1.15Mdiameter*12.11M length *Total weight of turbogenerator:428 Tons

SALINT DESIGN FEATURES:Air Cooled Turbo Generators Up to 200 MW Range:*Stator core and rotor winding direct air cooled. *Indirect cooling of stator winding. *Horizontally split casing design of stator *Vertically side mounted cooler in a separate housing. *Micalastic bar type insulation system. *Separately assembled stator core and winding for reducing the manufacturing cycle. *Brushless/static excitation system. Hydrogen&Water-Cooled Turbo Generators Of 200-235MW range:*Stator winding directly water cooled. *Rotor winding directly hydrogen cooled by gap picks up method. *Resilientley mounted stator core on flexible core bars. *Thermo reactive resin rich insulation for stator winding. *Top ripple srings in stator slots. *Enclosed type slip rings with forced ventilation. *Ring/thrust type shaft seal. *Two axial fans systematic ventilation and four hydrogen coolers. *Static excitation.

Hydrogen Cooled Turbo Generators Of 140-260 MW range:*Stator core and winding directly hydrogen cooled. *Indirect cooling of start winding. *Rigid core bar mounting. *Micalastc insulation system. *End shield mounted bearings. *Top shield mounted bearings. *Ring type shaft seals. *Symmetrical ventilation. *Brushless/static excitation. *Integral coupling of rotor. Hydrogen&Water-Cooled Turbo Generators of 500 MW range:*Stator winding directly water cooled. *Rotor winding directly hydrogen cooled(axial). *Leaf spring suspension of stator core. *Micalastic insulation system. *End shield mounted bearings. *Supporting for stator over hang. *Magnetic shunt to trap end leakage flux. *Ring type shaft seals with double flow. *Brushless/static excitation. * Integral coupling of rotor.

FIG :- ASSEMBLED TURBO GENERATORS

DESIGN CONSIDERATIONS:2 pole machine 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 vibration. *brushless excitation system. *vertical hydrogen cooler. Salient technical data:*Rated output:588MVA,500MW *Terminal voltage:21KV *Rated stator current:16KA *Rated frequency:50HZ *Rated power factor:0.85 Lag *Efficiency:98.55%

4. TESTING
Testing has to be done on a machine at every step in its manufacturing process for the company to certify it to be a deliverable good. Test brings out the impact of process variations. Testing is done in simulations which tend to closely resemble the practical scenario under which the machine works. Testing provides the experimental data like the efficiency, losses, characteristics, temperature limits etc. In this report of mine we shall look into the different types of tests, which are currently in use at BHEL, which are being conducted on stator, rotor and exciter. 4.1 TYPES OF TESTING: Testing, in a generic sense can be classified into two different types, they are. 1. Process Testing (Tests conducted whilst manufacturing a machine). 2. Performance Testing (Tests conducted on a completed machine). Process and performance tests have been listed below in a generic sense. As we proceed further with this report, we shall discuss the various tests carried out on stator, rotor and exciter individually and in a better detail.

4.2 LIST OF PROCESS TESTS:

1. Ring flux test. 2. HV test. 3. Inter half test. 4. RTD test. 5. Resistance measurement. 6. Impedance test. 7. Tan test. 8. Lead to Lead and Lead to Body test. 9. Megger Test. 10. Measurement of shaft voltage. 11. Lamp test. 12. Diode testing.

4.3 LIST OF PERFORMANCE TESTS:

1. Mechanical run test. 2. Short circuit test. 3. Open circuit test. 4. Running impedance test. 5. Sudden short circuit test. Apart from the tests that have been mentioned above (conducting of those experiments is a mandate), upon the demand of the customer, the following tests are also conducted and these are termed as TYPE TESTS.

4.4 LIST OF TYPE TESTS

Measurement of Leakage reactance of stator winding. Heat run tests: a) Mechanical heat run test. b) Short circuit heat run test. c) Open circuit heat run test. Voltage waveform analysis and determination of Telephone harmonic factor (THF). Measurement of residual voltage of stator windings at rated speed. Line to Line sustained short circuit test and determination of Negative sequence Reactance (X2). Line to Line and to Neutral sustained short circuit test and determination of Zero Sequence reactance (X0). Retardation test for determination of GD2. Three phase sudden short circuit test at 30%En and determination of reactances and time constants.

4.5 STATOR TESTING

A stator serves as the armature for the synchronous generator. A stator is fundamentally tested for the detection of shorts in the coils (caused due to failure of insulation) and the insulation capacity along with the resistance, capacitance and ambient temperature of the stator are calculated.

fig.4.1 RINGFLUX TEST:

A cable is wound to the stator terminals; current is passed and increased to the stators rated value. Increase in temperature will be noted. An increase in temperature till 10c is allowed and if the temperature increases beyond this limit, it is an indication of an impurity at the core. This test is conducted to check for any impurities in the core.The stator core is then treated with H2 SO4 and a voltage of 25-50 V is applied across the terminals, impurities will burst out.

INTER HALF TEST:

When the coils are wound, they are so done in such a fashion that the end connections of the coil have a pair of copper sheets projecting out. In this test, the insulation between the two layers is checked.One layer is wounded by an aluminum strip and is supplied by phase; the other end will be connected to a bulb. If the insulation is good, then the bulb should not glow, if it does, the same test is carried out at further distance, if the problem still persists, the coil will be replaced. The same procedure is followed for all coils, once the bottom layer is laid, again when the top layer is laid, finally on the complete winding.

RESISTANCE MEASUREMENT: A 4-wire micro ohm meter is connected to different phases of the stator to obtain the total resistance of the coils in that phase. RTD MEASUREMENT:
RTD wires are connected to all the coils in the stator; they are used to calculate the ambient temperature of the stator. Using a digital multimeter in resistance mode, all the RTD coils are checked and from the obtained resistance the temperature is calculated from the following law. Until 100 the temperature will be 0c, but, from 100 , every 1 rise in resistance will represent 2.6c rise in temperature.

1.5.5 Tan TEST:

This test is conducted on a stator to obtain the unknown capacitance of the stator and its loss angle factor. The capacitance and Tan measurement of stator winding is done using Schering Bridge and a standard capacitor. For a 3 phase synchronous machine, the windings are symmetrical and the value of capacitance is obtained by the following method. The stator body is isolated from ground by placing insulation packing between the body and the base. Connections to the Schering Bridge, Standard capacitor, Null indicator and transformer are done for the selected arrangement. Measurements are taken at Voltages 0.2Un to 1.0Un in steps of 0.2Un. The H.T. supply is switched on and raised to the required value. The bridge is balanced with the proper selection of variable resistances (R3+S) & the capacitance C4 and readings are recorded. After all measurements, Voltage is reduced to zero, supply is switched off and windings are discharged to earth. Formulae used: i) Capacitance: Cx = {Cn* R4* (R3+100)}/{N (R3+S)} F ii ) Per cent tan : % Tan = ({ x R4*C4 ) x 10-4 x 100) Where, Cn and C4 are in F & R3 R4,N & S are in .

1.5.6 MEGGER TEST: (measurement of IR value)

In case of stator, the megger in use is a 1000/2500V megger. Megger is a high resistance bridge with a DC source. This test is usually done prior and after the HV test. The basic objective of this test is to check if the insulation resistance values of the insulations of the coils are up to the mark and obtain their values. This test is conducted on every phase. The expected resistance should be a minimum of (V+1) M (practically the value turns out to be much more than the prescribed value). [V has been defined in the forth coming section of HV test.] The process is that the phase that is under consideration is connected to the positive probe of the megger and the other two phases are shorted and connected to the negative probe of megger. When the voltage is applied across the terminals, the insulation resistance of that particular phase appears in the screen. The test is conducted on all three phases.

1.5.7 HV TEST:
This test is conducted to check if the insulation of the winding is capable of withstanding the high voltage supplied to it. The HV supplied will be calculated by the following formula.

V = (2v + 1) KV
The process remains same as that of the megger test except for the fact that the phase to be measured will be supplied with a HV and the other two phases will be grounded. The same procedure will continue for all three phases. While testing prior to manufacturing, before and after impregnation in the absence of the customer, the voltage applied will be 1.5 times of V. In the presence of the customer though, only V will be applied.One of the notable points here is that, before impregnation the HV applied will be DC and after impregnation the HV applied will be AC.

fig:4.2 The above graph shows the process of HV testing. For the first 20 sec the voltage is gradually increased to the desired HV. The HV is maintained for 1 minute an then drastically decreased.

The following is the STANDARD OPERATING PROCEDURE of STATOR TESTING employed at BHEL. APPARATUS:
MEGGER, high potential tester, with adjustable power supply, compensation reactance if required, HV transformer, Earthing rod, and compensator rods for making connections.

PROCEDURE:
1. Calculate V, where V = (2v + 1) KV where V is the final test voltage after test run. v is the rated voltage of the generator. 2. Connecting rings are tested with 1.2* V for 1 minute. If there is sparking due to less distance between live points, the same can be done with 1.1*V. if connecting rings are assembled after laying the bars, they are to be tested along with the bars. The HV is given to the copper and the core is earthed. The o/p voltage of the HV tester is continuously increased to test the voltage level, held at this level for 1 min and subsequently decreased to initial level. 3. After laying the bottom bars, 1.15* V HV is applied for 1 minute. 4. Individual strips of each bar are tested with 110V AC for inter half shorts and inter bundle shorts with same voltage. 5. After laying the top bars HV testing with 1.1* V for 1 min. 6. Individual strips of each bar are tested with 110V AC for inter half shorts and inter bundle shorts with same voltage for top bars only. 7. After connecting the top and bottom bars but without connecting to the connecting rings, conduct inter half short test with 110V AC 8. After completion of the winding and baking, Conduct HV test of individual phases with 1.05* V for 1 min when one phase is under earthing the other phases are earthed. Measurement of R of individual phases. Measurement of the individual phases. 9. After test run, HV testing for individual phases with 1.0 * V for 1 minute.

NOTE: Where ever bunch brazing is employed for connecting top and bottom layers, only inter half test is to be carried out. During HV test, the phases except the measuring phase have to be earthed. IR value of the insulation should be 25 M {KV+1} at least and is to be calculated by a 1000/2500 V megger.

1.6 ROTOR TESTING

Refer fig iii for the block representation of the construction of rotor. A rotor is tested for mechanical losses, winding short circuits, inter turn shorts, total insulation resistance of the rotor. Rotor in a synchronous generator serves the purpose of providing the field. Before going any further lets briefly discuss the various insulations required to be placed between the conductor and core. For the given machine (11KV), the following insulation is employed. Mica 1 layer 0.25mm. Internal corona tape 1 layer 0.30mm. Copper strip 0.02mm 1layer. Mica 8 layers 0.25mm. Outer corona tape- -0.25mm 1 layer. Split mica 1mm 1 layer. Outer corona tape 0.25mm 1mm. The above given list is the scheme in which the layers of insulations are arranged.

LEAD TO LEAD & LEAD TO BODY TEST:

There exists a DC lead inserted in the rotor. This lead is a couple of semi non-hollowcylinders separated by a thick layer of insulation and bounded by another layer of thick insulation. In this test the insulations mentioned above are tested. In the LEAD TO LEAD test, one lead is grounded while the other is supplied by a HV; this is maintained for 1 minute. Any insulation failure will results in penetration of holes. In the LEAD TO BODY test, the leads are shorted and are supplied by a HV, while the rotor body is grounded, any short will results in, penetrations.

fig:4.3

IMPEDANCE TEST:
This test is to check the existence of inter turn shorts. Two different windings in the same slot are connected to the phase and neutral of a power supply with 230V and 500Hz, for 1 minute. Any inter turn shorts are detected by this test. Shorts, if any are detected by connecting a Digital multi meter (voltage will be nullified) and that particular slot is sent for re-winding and insulation. This test did not demand any importance till the early 1980s, since late 1980s this test was identified to be of utmost importance and since then this test has been of utmost importance in the electrical testing department at BHEL.

HV TEST:
This test is conducted to measure the total insulation of the rotor. A voltage which is equal to ten times the rotors rated voltage is applied across the rotor leads; the applied voltage is applied in an exactly same fashion as that of the STATOR.

U = 10*v
From the above equation, U = standard test voltage, v

= rated voltage of the

machine.

MEGGER TEST:
The test process remains same as that of the HV test except for the fact that only a small DC voltage replaces a high voltage AC. A 500/1000V megger is used here and the insulation capacity is checked for the execution of HV test. Both the leads of rotor are connected to the two ends of megger (none are grounded).This test is conducted before and after HV test.

RESISTANCE MEASUREMENT:
This test is to measure the resistance of the conductors of the rotor. The test process is similar to that of the stator except for the fact that the meter will be connected to the leads.

MECHANICAL RUN TEST:

This test is carried out in the BALANCING TUNNEL, just adjacent to testing area, where the rotor is made to run at 20%, 30%, 60%, 90% and 100% of its rated speed and is checked for any mechanical imbalances, which can be identified by the vibrations while the rotation take place. Now that the context has come, we shall have a glance at balancing tunnel too.

Fig: 4.4

Balancing tunnel is used to detect any mechanical imbalances in the rotor as they will cause heavy damage. The rotor is kept on a pedestal with wheels and is sent into the tunnel where it will be mechanically coupled to a DC Drive with whose support the rotor rotates. Lubricating oil will be introduced at the bearings so as to avoid any friction, at the surface of contact of the rotor ad bearings. The rotor, bearings, oil flow, temperature detector (at the ceiling), cameras (attached to the ceiling of the tunnel), vacuum motor (sucks all the air out of the tunnel and maintains I torr of vacuum pressure), cooling systems and the thyristor systems with the circuit breaker systems are connected to the control cum monitoring panel and the door is closed. The capacity of the balancing tunnel at BHEL is 50 tonnes and 20000 rpm. At rated speed, the rotor takes a lot of shapes due to imbalances an the allowed range of vibrations is 50 microns, while practically it can be reduced to 1.5 microns. Generally, the best way of minimizing vibrations is weight manipulation and weight addition is universally accepted procedure rather than weight reduction. Whilst manufacturing, a rotor is provided with certain holes called balancing holes exactly for this purpose. Generally imbalances are identified horizontally, axially and vertically and a weight which is of the same value as that of the imbalance is added to the other side in the exact opposite side to compensate the imbalance.

SHORT CIRCUIT CHARACTERISTICS:

A couple of current transformers are connected between one ends of the 3 phases while the other ends are shorted. The machine is run at rated speed and a current equivalent to 20% 40% 60% 80% 100% of the rated current is made to pass through the rotor and the reading on the current transformers are noted. OPEN CIRCUIT CHARACTERISTICS: The procedure remains same as short circuit characteristics except for some changes like potential transformers replace current transformers and a voltage equivalent to 20% 40% 60% 80% 100% of the rated voltage is applied across the terminals of the rotor and the corresponding readings are obtained at the potential transformers.

RUNNING IMPEDANCE TEST:

This test checks the inter turn insulation of the rotor windings when it is running, as the rotor running at rated speed might displace the insulation. While the rotor is running at rated speed a 230V 500Hz supply is given through a couple of temporary slip rings at the rotor shaft and the voltage readings are taken at the same with a digital multimeter. Any inter turn shorts as such will be detected.

The Following is the STANDARD OPERATING PROCEDURE of ROTOR TESTING employed at BHEL: APPARATUS:
Megger, high potential tester with adjustable Power supply, HV transformer, voltmeter, earthing rod and copper wires for making connections.

PROCEDURE
1.

U = 10*v
From the above equation, machine.

= standard test voltage,

v =

rated voltage of the

2. Before assembly in the rotor bore. Pole against HV testing with (U+2000) Both poles against earth HV testing with

V AC for 1 min. (U+3000) V AC for 1 min.

3. After assembly in the rotor bore. Pole against HV testing with (U+1500)

V AC for 1 min. With both poles against earth, conduct HV testing with (U+1500) V AC

for 1 min. 4. After assembly of 2 coils on each pole. HV test with (U+1000) V AC for 1 min. Inter turn shorts with 75V AC per coil at 500 HZ. 5. Winding before wedging. HV test with (U+900) V AC for 1 min. Inter turn shorts with 50 AC per coil at 500HZ. 6. Winding after wedging. HV test with (U+800) V AC for 1 min. 50 V 500 Hz Ac inter turn shorts. 7. After pressing and curing the insulation under retaining ring. HV (U+600) V AC for 1 min. 50 V 500 Hz Ac inter turn shorts DC winding resistance measurement. 8. After mounting slip rings. HV (U+200) V AC for 1 min. 9. After mounting retaining ring. HV against shaft with (U+400) V AC for 1 min. Inter turn shorts with 50 AC per coil at 500HZ DC winding resistance measurement. 10. Over speeding and balancing at stand still.

 HV (U+200) V AC for 1 min. Impedance measurement of rotor at 50 Hz. DC winding resistance measurement. HV (U+500) V AC for 1 min at 3000 rpm. 11. After test run. HV (U) V AC of the winding against shaft for 1 min. 12. Record test results. NOTE: Measure IR values of the winding insulation before and after each HV testing. Minimum IR value should approximately be 4M, use a 500/1000 megger.

4.7 EXCITER TESTING:

Refer fig (iv) for the block representation of manufacture process of an exciter.

fig:4.5

The exciter in the discussion is a 583 KW, 550V, 1060A, 750rpm KWU type exciter. In a practical scenario, exciter serves the purpose of providing the excitation current to the rotor for the turbo alternator / synchronous generator to excite and produce electricity and is driven by the rotor of the synchronous generator to which it is mechanically coupled. In the testing area, however, we make use of a DC DRIVE to serve the purpose of the rotor. For working of the exciter please refer the Para following fig (i). Before an exciter is tested it should first be magnetized.

MAGNETIZATION OF PMG:
A cable is wound onto the Permanent magnet Generator (PMG) poles and a DC voltage is applied to it, this will trigger a magnetic field at the poles. This is not only a routine activity but also a test that verifies the nature of the metal used to construct a PMG.

Fig: 4.6 LAMP TEST:

This test is specifically for the yoke and is conducted to verify that there is no individual coil breakage. A lamp is placed to one end of a wire which is connected to neutral and all the coil terminals are shorted, the other end of the wire is connected to the last terminal of all the PMG coils and is supplied with voltage. If the bulb glows, it means that there is no breakage in the coils, else, the yoke should undergo a thorough retrospection and should be reworked.

Fig: 4.7 IMPEDANCE TEST:

Testing procedure of this test remains the same as that of its counterparts i.e. stator and rotor. This test is conducted on the rotor (armature) and the stator (field). Inter turn shorts of the armature and the stator are detected (if any) and rectified.

MEGGER TEST:
The megger used here is a 2.5KV megger. Intention of conducting this test is obviously same as that which were done on the rotor and stator, the ac lead and the stator are connected to the megger and the insulation capacity is verified. This test, too, is conducted before and after HV test.

HV TEST:
This test is conducted to obtain overall insulation resistance of the armature. The HV is applied to the AC lead observed between rotor and the rectifier wheel, and the stator is grounded.

The voltage applied is obtained by the following formula,

(V = (10v) KV) where V is the final test voltage and v is the rated voltage of the exciter.
The remaining process remains same as that of the rotor of generator. This test is conducted before and after the armature is impregnated.

RESISTANCE MEASUREMENT:
This is conducted to the stator and the rotor of the exciter and the process remains same as that of the process applied for the ROTOR of the generator.

DIODE TEST:
The Diodes used here are of 400A, 750V rating and 28 diodes are connected in a wheel with 7 bridge connections.

Fig: 4.7 All diodes are individually tested using a multi meter, the criterion is that one terminal should indicate high and the other should indicate zero.

The following is the STANDARD OPERATING PROCEDURE employed for EXCITER TESTING at BHEL APPARATUS:
HV tester (ac & dc) with adjustable power supply, HV transformer, voltmeter, micro ohm meter, impulse generator and 2.5 KV megger.

PROCEDURE 1. V = (10v) KV where V is the final test voltage and v is the rated voltage of the exciter. 2. Core tension balls vs. earth after assembly to be tested with 1000 V AC for 1 minute.

3. All connecting rings to be tested against each other and against earth with 1.2V AC for 1 minute. 4. DC HV test on armature. After laying the coils and wedging with 2.5 KV Dc for 1 minute. (winding vs. earth) After brazing and before connecting rings with 2KV DC for 1 min. (phase vs. phase & phase vs. earth) 5. Measurement of ohmic R before impregnation. 6. Measurement of R after impregnation & before bandage. HV testing of winding with 1.2*V for 1 minute. (connecting rings to be provisionally connected for testing purposes, phase vs. phase & phase vs. earth) Measurement of ohmic R. 7. After bandage and after brazing the connecting rings to the winding. Winding to be tested with 1.2 *V AC for 1 minute against earth on the non magnetic steel with bandage. Measurement of ohmic R. 8. After shrink fitting the wound armature on the shaft. 1.15*V AC for 1 minute against earth. 9. Measuring slip rings (against each other ) and the corresponding leads(against earth) to be tested with 1.2*V for 1 minute. 10. HV for AC lead assembly. After assembly before bandage V+1500 V AC for 1 min. After bandage HV with 1.2* V AC for 1 minute. 11. After mounting, rectifier wheel is to be tested with 1.2* V AC for 1 minute against earth. 12. Heat sinks(without diodes) to be tested again rectifier wheel with 1.15*V AC for 1 minute. 13. Total inverse current of rectifier wheel A and B to measured with 1000V dc. 14. Before balancing and over speeding all electrical active components to be tested with 1.1* V for 1 min. ( AC to DC leads shorted during this HV testing) 15. After balancing and over speeding, all electrical active components to be tested against earth with 1.05*V for 1 minute. (AC to DC leads shorted during this HV testing) 16. Total inverse current of rectifier wheel A and B to measured with 1000V dc. 17. After magnetizing the PMG poles, the polarities are to be checked. 18. After painting and drying, resistances of the fuses are to be measured and total inverse current of rectifier wheel A and B to be measured with 1000V dc. 19. After test run all electrical active components to be tested with V for 1 min. ( AC to DC leads shorted during this HV testing), resistances of the fuses are to be measured and Total inverse current of rectifier wheel A and B to measured with 1000V dc. NOTE: HV on Dc lead assembly is to be carried out as per rotor. IR value before and after each HV is to be 50M atleast and is to be so done using a 2.5 KV megger.

4.8 SUDDEN SHORTCIRCUIT TEST:

Apart from the above mentioned tests for rotor, stator and exciter, there are two type tests that have gained importance amongst the clients; one of them is the sudden short circuit test, the other being mechanical heat run test.

LINE

TO

LINE

SUSTAINED

SHORT

CIRCUIT

TEST

AND

DETERMINATION OF NEGATIVE SEQUENCE REACTANCE (X2):

The line to line sustained short circuit test is carried out by short circuiting two line terminals of stator, using CT. The machine is driven at rated speed and excited. The following parameters are recorded at three values of short circuit current (limited to 30% of rated current). a) Short circuit current (Ik2) through current transformer. b) Voltage between the open line terminal and one of the short-circuited terminals (Uk2) through potential transformer (not used in calculation). c) Active power P.

EVALUATION OF NEGATIVE SEQUENCE REACTANCE (X2):

Negative sequence reactance is calculated as follows i) X2 = P/{ 3 . (Ik2)2} where, P : Power measured during the test. Ik2 : Line to line short circuit current measured during the test. ii) %X2 = (X2/Xn)x100 Note: Minimum time is taken for tests because serious rotor surface heating may result if current is sustained for a longer time or raised to too high a value.

LINE TO LINE AND TO NEUTRAL SUSTAINED SHORT CIRCUIT TEST AND DETERMINATION OF ZERO SEQUENCE REACTANCE (X0):
The line to line and to neutral sustained short circuit test is carried out by short circuiting two line terminals and shorted to neutral, using C.T. The machine is driven at rated speed and excited. The following parameters are recorded at several values of short circuit current limited to 30% of rated current. a) The neutral current (Io) through current transformer. b) Voltage between the open line terminal and neutral (Vo) through potential transformer.

EVALUATION OF ZERO SEQUENCE REACTANCE (X0):

Zero sequence reactance is calculated as followXo = Vo/Io where, Vo : Line (which is in open condition) to neutral voltage measured during the test. Io : Line to neutral current measured during the test. ii) %Xo = (Xo/Xn) x 100.

4.9 MECHANICAL HEAT RUN TEST:

This test too, is a type test which has gained enormous importance amongst the clients. The machine is rolled and run at rated speed after ensuring the bearing oil (seal oil, cooling water to coolers - for hydrogen cooled m/cs only) and kept at rated speed for stabilization of temperatures. Temperatures of stator inbuilt RTDs, bearing oil, bearing metal, cold air and hot air are monitored normally through Data Acquisition System. Periodically, the readings are taken at interval of 15 minutes. The temperatures are confirmed to be stabilized, if the temperature rise over cold air in one hour is not more than 2 C.

MEASUREMENT OF ROTOR TEMPERATURE:

As it is a rotating part of the machine, the measurement of rotor winding temperature is done by measuring the rotor resistance using voltage divided by current method. For voltage measurement, to minimize error, one set of brushes on slip rings are kept isolated (insulated from remaining current carrying brushes) and voltage is measured across these brushes i.e. directly across the slip rings. Before start of run test, in cold state giving excitation to the rotor, current and voltage are noted. The ohmic resistance of rotor is computed along with the cold air temperature. R20 (i.e. rotor resistance at 20 C) is calculated and this becomes the base for temperature rise calculation during the heat run. Periodically, the excitation is injected to rotor winding and rotor resistance is calculated by noting down voltage and current.

EVALUATION OF STATOR TEMPERATURE RISE:

Temperature rise = Stabilized temperature - cold air temperature (average).

EVALUATION OF ROTOR TEMPERATURE RISE:

Rotor temperature rise = {(Rt/R20) 255 - 235} - Cold air temperature (average)where, Rt : Stabilized rotor resistance in . R20 : Rotor resistance at 20 C in .

SHORT CIRCUIT HEAT RUN TEST:

After mechanical heat run test, preparation for short circuit heat run test is made. The machine is run at rated speed and excited to 100%In. The machine is kept under this state for temperature stabilization.

EVALUATION OF STATOR TEMPERATURE RISE: Temperature rise = Stabilized temperature - cold air temperature (average).

EVALUATION OF ROTOR TEMPERATURE RISE:

As excitation is available continuously, measurement of rotor voltage and current are done periodically. Evaluation of temperature rise is done in same way as above.

OPEN CIRCUIT HEAT RUN TEST:

After short circuit heat run test, preparation for open circuit heat run is made The machine is run at rated speed and excited to 110%En. Machine is kept under this state for temperature stabilization

5. RESULTS
Test result of one of the 115 MW turbo alternator have been listed below, the clients name, date of testing, rating of the material, name of the test, graphical representation and other details have been given in the scanned files of the original BHEL REPORTS. The ratings of the said machine are given below. TURBO ALTERNATOR / SYNCHRONOUS GENERATOR

115 MW, 143.75 MVA, 11 KV, 7545 Amps, 0.80 pf, 3000 rpm, 2EXCITER: 583 KW, 550V, 1060A, 750rpm KWU type.

CONCLUSION
CONCLUSION:
The Vocational training at BHEL Hyderabad helped us in improving our practical knowledge and awareness regarding Turbo Generator to a large extent. Here we came to know about the technology and material used in manufacturing of turbo generators. Besides this, we also visualized the parts involved or equipments used in the power generation. Here we learnt about how the electrical equipments are being manufactured and how they tackle the various problems under different circumstances. At least we could say that the training at BHEL Hyderabad is great experience for us and it really helped us in making or developing our knowledge about turbo generator and other equipment used in power generation. Since more than 100 years turbo generators have been in use for stem turbine and gas turbine applications of any size. The technical evolution has not stopped,new market reqirements and new material technologies ask for adaptions in design.The future market will be characterized by a revitalized need for very large turbo generators,both 2-pole and 4-pole. The future will also be characterized by an exciting competition between well-established conventional solutions and new high tech solutions.In any case highly skilled engineers paired with the best available design tools will be required.

FUTURE SCOPE:
The technology research and investigations division of BHEL is currently investigating the technical and logistical merit of performing offline quadratic-rate partial discharge tests on the stator winding insulation of its hydro & turbo generators. A series of laboratory based insulation research studies on stator bars have been conducted to gain a better understanding of the various partial discharge phenomena involved.