ACKNOWLEDGEMENT

An engineer with only theoretical knowledge is not a complete engineer. Practical

knowledge is very important to develop and apply engineering skills. It gives me a great
pleasure to have an opportunity to acknowledge and to express gratitude to those who were
associated with me during my training at BHEL.
Special thanks to Mr.RAJMANI JAISWAL for providing me with an opportunity to
undergo training under his able guidance.
I express my sincere thanks and gratitude to Mr. Harpreet singh ( HOD ,Electrical
Department) & Er. Sahi Ram along with BHEL authorities for allowing me to undergo
the training in this prestigious organization. I will always remain indebted to them for
their constant interest and excellent guidance in my training work, moreover for providing
me with an opportunity to work and gain experience.

Aditya Vidyarthi
Electrical Engineering
12EIAEE002
IET, ALWAR

INSTITUE OF ENGINEERING AND TECHNOLOGY

Department of Electrical Engineering
Alwar -301030

CANDIDATE DECLARATION
I, Aditya Vidyarthi hereby declare that the work, which is being presented in the report
entitled Manufacturing of turbo generators in the partial fulfillment for the award of
degree of Bachelor of Technology in the department of Electrical engineering ,
Institute of Engineering and Technology , Alwar affiliated to Rajasthan Technical
University is a record of my own investigation carried under the able guidance of Mr.
Rajmani Jaiswal at BHEL, Haridwar.
I hav not submitted the matter presented in this report anywhere else for the award of any
other degree.

Aditya Vidyarthi
Roll no 12EIAEE002

Counter sign By:Er. Sahi Ram

(Seminar Incharge)

ii

INSTITUE OF ENGINEERING AND TECHNOLOGY

Department of Electrical Engineering
Alwar -301030

CERTIFICATE

This is to certify that Mr. Aditya Vidyarthi, Roll No 12EIAEE002 a student of Bachelor of
Technology, 7the semester of this institute has completed the Industrial Summer Training
at BHEL , Haridwar of 60 days duration in partial fulfillment of Bachelor of Technology
degree program of Institute of Engineering and Technology, Alwar .

Counter Sign by:

Er. Sahi Ram
(Seminar Incharge)

iii

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.

Aditya Vidyarthi
Electrical Engineering
IET, Alwar

iv

LIST OF CONTENTS
I. Acknowledgement
II. Certificate
III. List of Contents

1. Bharat Heavy Electricals Limited

1.1

BHEL- An Overview

1.2

Different Blocks at BHEL

1-5

2. Introduction to Turbo-Generators

6-12

2.1

Turbo-Generator

2.2

Sizing of Generator module

2.3

Synchronous generator classification

2.4

Generator Module Nomenclature

2.5

Generator module

2.6

Components used in Turbo-Generator

3. STATOR
3.1

Stator frame

3.2

Stator core

3.3

Lamination preparation

3.4

Assembly of Core

3.5

Stator binding

3.6

Stator end Cover

3.7

Bushings

3.8

Generator Terminal Box

12-21

4. ROTOR
4.1

Parts of Rotor

4.2

Rotor winding

4.3

Insulation

4.4

Rotor slot wedges

4.5

Rotor retaining rings

4.6

Field connection

4.7

Rotor fan

22-29

5. EXCITATION SYSTEM
5.1

Brushless Excitation

5.2

Pilot Exciter

5.3

Main Exciter

5.4

Rectifier Wheel

5.5

Flow Chart

5.6

Advantages of brushless excitation

30-35

6. COOLING SYSTEM

35-38

6.1

Cooling methods for turbo generators

6.2

Air cooled turbo generators

6.3

Hydrogen cooled

7. GENERATOR TECHNICAL DATA

39

8. TESTING OF TURBO GENERATOR

40-44

9.

8.1

Short circuit test

8.2

Open circuit test

8.3

Inter strand test

8.4

High voltage test

8.5

Helium test

CONCLUSION

45

10. REFERENCES

46

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