TECHNICAL TRAINING REPORT

SUMMER INTERNSHIP 2017

AT

Submitted By
Stuti Shrivastava
151020012015

Electrical Dept .
5th -17th June’17
 TECHNICAL TRAINING REPORT
SUMMER TRAINING 2017
AT

Submitted By
Avani Hardikar
0801ME151017
Mechanical Dept.
5th -17th June’17
ACKNOWLEDGEMENT
The internship opportunity I had with ANDRITZ HYDRO was a great chance for learning and
professional development. Therefore, I consider myself as a very lucky individual as I was provided
with an opportunity to be a part of it. I am also grateful for having a chance to meet so many
wonderful people and professionals who led me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and special
thanks to Mr. Ajay Pandey, the HR of ANDRITZ HYDRO who in spite of being extraordinarily
busy with his duties, took time out to hear, guide and keep me on the correct path and allowing me to
carry out my training at their esteemed organization.

I express my deepest thanks to Mr. M.B. Daflapurkar for taking part in useful decision & giving
necessary advices and guidance and arranged all facilities to make life easier. I choose this moment
to acknowledge his contribution gratefully.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to

Mr. Danish Khan, Mr. Shagir Ali, Mr. Dinesh Tiwari, Mr. Pawan Pandey, Mr. Sanjeev Shrivastav
Mr. Ramesh Patel and Mr. Alok Soni for their careful and precious guidance which were extremely
valuable for my study both theoretically and practically.

I would like to appreciate all the operators and technicians of the industry for their constant
encouragement and valuable solutions to my doubts during the training period.

I perceive as this opportunity as a big milestone in my career development. I will strive to use gained
skills and knowledge in the best possible way, and I will continue to work on their improvement, in
order to attain desired career objectives. Hope to continue cooperation with all of you in the future.
Table Of Contents
1. Title Page
2. Acknowledgement
3. Table of contents

4. Company Profile
I. History
II. ANDRITZ Today
III. Indian Scenario

5. Hydro Power Generation

A. Hydro electric Power
I. World distribution of hydro power
II. Advantages of hydro power
III. Disadvantages of other sources of power
IV. Disadvantages of hydro power
V. Hydro power and the environment
B. Classification of hydro power plants
C. Classification on the basis of facility types
D. Plant Configuration

6. Turbines
I. Main Parts of a turbine
II. Working Principle
III. Classification of turbines
IV. Pelton Turbine
V. Francis Turbine
VI. Kaplan Turbine

7. Generators
I. Synchronous Generators
II. Construction
III. Working Principle
IV. Types of Generators
V. Basic Components
8. Pole Shop
 Pole Coil
 Pole Body
 Pole Assembly

9. Coils and Bars Shop

I. Roebelling
II. Consolidation: Heating and Pressing
III. Forming and Bending
IV. Induction Brazing of end plates
V. Insulation

10.Generator Assembly Shop

 Stator Frame
 Stator Core
 Stator Sheets
 Rotor
 Laminated Poles

11. Vacuum Pressure Impregnation

 VPI Process
 VPI Benefits

12.Automation Technology

13.Quality Assurance and Safety

COMPANY PROFILE
ANDRITZ is a globally leading supplier of plants, equipment, and services for hydropower stations,
the pulp and paper industry, the metalworking and steel industries, and for solid/liquid separation in
the municipal and industrial sectors. In addition, ANDRITZ offers technologies for certain other
sectors including automation, the production of animal feed and biomass pellets, pumps, machinery
for nonwovens, steam boiler plants, biomass boilers and gasification plants for energy generation,
flue gas cleaning plants, plants for the production of panel boards (MDF) and thermal sludge
utilization. The publicly listed technology Group is headquartered in Graz, Austria, and has a staff of
around 25,700 employees. ANDRITZ operates over 250 sites worldwide.

I. HISTORY
From a small iron foundry to a globally leading technology group
The cornerstone of today’s international technology Group ANDRITZ was laid in 1852 when a small
iron foundry was set up in Graz, Austria. The milestones in the history of ANDRITZ are outlined
here.
 1852-1900: beginnings as an iron foundry
ANDRITZ AG has its origins in an iron foundry that was established in 1852 by the
Hungarian entrepreneur Josef Körösi in Andritz, a suburb of the city of Graz. Soon after its
foundation, the company’s production program was extended to include large capital goods,
such as cranes, pumps, water turbines, and later also bridges, steam boilers and engines, as
well as mining equipment.

 1900: ANDRITZ becomes a stock corporation

 1900-1946: World Wars and the Great Depression

At the end of the First and Second World Wars and during the Great Depression in the early
1930s, ANDRITZ’s production came to a standstill, but the company’s dedicated
management and employees succeeded each time in making a new start.

 1946-1980: growth and new products

In 1949, ANDRITZ began a lasting cooperation with the Escher Wyss Group of Switzerland,
initially in the water turbines sector. The product portfolio of ANDRITZ was revised:
Production of steam engines and air compressors came to an end, and the focus shifted
towards water turbines, centrifugal pumps, cranes, and steel structures. In 1951, ANDRITZ
embarked on the production of complete paper machines in cooperation with Escher Wyss.
In 1950, Creditanstalt-Bankverein, Austria, acquired a majority interest in ANDRITZ.
During the 1960s and 1970s, ANDRITZ continued to grow. The production shops were
extended, new machines purchased, and research and development activities intensified.
Electrochemical and metallurgical equipment were added to the production program.
  1980s: crisis and recovery
The second global oil crisis and worldwide economic stagnation in the early 1980s caused a
drop in ANDRITZ’s order intake and the company was operating at a loss, but Austrian
government subsidies and drastic rationalization measures enabled the company to survive.
In 1987, AGIV AG, an investment company in Frankfurt, Germany, acquired a majority
stake in ANDRITZ. ANDRITZ began to change its strategic direction, from being a licensee
of other equipment manufacturers to become a leading international supplier of its own high-
tech production systems.

 1999: change of ownership

AGIV AG sold its shareholding in ANDRITZ to a consortium of investment companies (The
Carlyle Group, GE Capital, Unternehmensinvest AG, Deutsche Beteiligungs AG) and the
Custos private foundation (established by Wolfgang Leitner, President and CEO of
ANDRITZ).

 2001/2003: listing on the Stock Exchange

In 2001, ANDRITZ went public on the Vienna Stock Exchange. Two million new shares
were placed successfully with national and international investors.
2003 saw the Secondary Placing of ANDRITZ shares on the Vienna stock exchange. The
financial investors sold their entire shareholdings in ANDRITZ, which resulted in a rise in
free float to around 70%.

Growth through acquisitions and research & development

In 1990, the acquisition of Sprout-Bauer, a US company supplying equipment for mechanical pulp
and animal feed production, marked the beginning of the Group’s successful expansion policy
through acquisitions. Complementary acquisitions, in addition to organic growth that is mainly
driven by research and development, have been an important driver of company growth ever since.

Since 1990, ANDRITZ has acquired and integrated almost 70 companies, pursuing its policy of
complementary acquisitions. The largest transactions in terms of sales were the acquisitions of
Ahlstrom Machinery Group in 2000/2001 (making ANDRITZ a globally leading supplier of pulp
production systems), of VA TECH HYDRO in 2006 (advancing ANDRITZ to a globally leading
supplier of electromechanical equipment for hydropower plants), and of more than 95% of Schuler,
the world market leader in forming technology, in 2013.

II. ANDRITZ today

ANDRITZ is a globally leading supplier of plants, equipment, and services for hydropower stations,
the pulp and paper industry, the metalworking and steel industries, and for solid/liquid separation in
the municipal and industrial sectors as well as for animal feed and biomass pelleting. Other important
business segments include automation and service business. In addition, the international Group is
also active in the power generating sector (steam boiler plants, biomass boilers, recovery boilers, and
gasification plants) and in environmental technology (flue gas cleaning plants) and offers equipment
for the production of nonwovens, dissolving pulp, and panelboard as well as recycling plants. The
publicly listed technology Group is headquartered in Graz, Austria, and has a staff of approximately
25,200 employees. ANDRITZ operates more than 250 sites in over 40 countries.
 III. INDIAN SCENARIO

 ANDRITZ HYDRO has been active in the Indian market for more than 100 years. The first
equipment deliveries took place for HPP Sivasamudram in 1903. Mid-1970, ANDRITZ
HYDRO opened an office in the city of Mandideep.
 ANDRITZ HYDRO was established in 1996 through a joint venture between ELIN Austria
and Crompton Greaves India for all types of generators. With the take over of the crompton
greaves' shares the entity later became part of of VA TECH hydro, Austria. After strategic
mergers and acquisitions in the subsequent years and the takeover of VA TECH hydro by the
ANDRITZ GROUP, ANDRITZ HYDRO Pvt. Ltd was renamed in 2008.

ANDRITZ HYDRO Pvt. Ltd has two fully equipped state-of-the-art manufacturing facilities located
at Mandideep and Prithla. Over 1,500 employees - highly qualified engineers and technicians -based
in India, Nepal, Vietnam, Malaysia, Indonesia, Philippines, Lao PDR, and Myanmar guarantee the
high quality of ANDRITZ HYDRO’s products and services.

 Mandideep: The facility located near Bhopal is manufacturing generators, excitation, automation,
control, and protection systems.
 Prithla: The facility located near Faridabad is manufacturing all types of hydropower turbines, large
butterfly- and spherical valves, providing state of the art coating technology as well governors and
control systems.
HYDRO POWER GENERATION
I. HYDROELECTRIC POWER

Although most energy in the world is produced by fossil-fuel and nuclear power plants,
hydroelectricity is still important, accounting for about 17.5% of total energy production. Nowadays,
huge power generators are placed inside dams. Water flowing through the dam spins the turbine
blades (made out of metal instead of leaves) which are connected to generator. Power is produced
and is sent to homes and businesses.

World distribution of hydropower

 Hydropower is the most important and widely-used renewable source of energy.

 Hydropower represents about 16% of total electricity production.
 China is the largest producer of hydroelectricity, followed by Canada, Brazil, and the United
States.
 Approximately two-thirds of the economically feasible potential remains to be developed.
Untapped hydro resources are still abundant in Latin America, Central Africa, India and
China.

Advantages to hydroelectric power

 Fuel is not burned so there is minimal pollution

 Water to run the power plant is provided free by nature
 Hydropower plays a major role in reducing greenhouse gas emissions
 Relatively low operations and maintenance costs
 The technology is reliable and proven over time
 It's renewable - rainfall renews the water in the reservoir, so the fuel is almost always there

Disadvantages to power plants that use coal, oil, and gas fuel

 They use up valuable and limited natural resources

 They can produce a lot of pollution
 Companies have to dig up the Earth or drill wells to get the coal, oil, and gas
 For nuclear power plants there are waste-disposal problems

Hydroelectric power is not perfect, though, and does have some disadvantages:

 High investment costs

 Hydrology dependent (precipitation)
 In some cases, inundation of land and wildlife habitat
 In some cases, loss or modification of fish habitat
 Fish entrainment or passage restriction
 In some cases, changes in reservoir and stream water quality
 In some cases, displacement of local populations
Hydropower and the Environment
Hydropower is non polluting, but does have environmental impacts

Hydropower does not pollute the water or the air. However, hydropower facilities can have large
environmental impacts by changing the environment and affecting land use, homes, and natural
habitats in the dam area.

Most hydroelectric power plants have a dam and a reservoir. These structures may obstruct fish
migration and affect their populations. Operating a hydroelectric power plant may also change the
water temperature and the river's flow. These changes may harm native plants and animals in the
river and on land. Reservoirs may cover people's homes, important natural areas, agricultural land,
and archaeological sites. So building dams can require relocating people. Methane, a strong
greenhouse gas, may also form in some reservoirs and be emitted to the atmosphere.

II. CLASSIFICATION OF HYDRO POWER PLANTS

 According to capacity
 Low
 Medium
 Small
 Mini
 Micro
 Piko
 According to head
 High
 Medium
  Low
 According to purpose
 Single purpose
 Multi purpose
 According to facility types
 Run of river
 Conventional storage
 Pump storage
 Hydromatrix
 According to hydrological relation
 Single
 Cascade
 According to transmission system
 Isolated
 Connected to grid

III. CLASSIFICATION ON THE BASIS OF FACILITY TYPES

 Run-of-river hydropower: a facility that channels flowing water from a river through a
canal or penstock to spin a turbine. Typically a run-of-river project will have little or no
storage facility. Run-of-river provides a continuous supply of electricity (base load), with
some flexibility of operation for daily fluctuations in demand through water flow that is
regulated by the facility.

 No storage capacity
 Near dam or lake outlet
 Natural river flow controlled
 Available flow governs capacity

 Conventional-storage hydropower: typically a large system that uses a dam to store

water in a reservoir. Electricity is produced by releasing water from the reservoir through a
turbine, which activates a generator. Storage hydropower provides base load as well as the
ability to be shut down and started up at short notice according the demands of the
system (peak load). It can offer enough storage capacity to operate independently of the
hydrological inflow for many weeks or even months.

 Multi purpose
 Power generation
 Flood control
  Irrigation
 Significant storage capacity
 Weekly
 Seasonal
 Controls river flow
 Levels out the river flow
 Saves flows larger than plant capacity (avoid spill)
 Catch in wet seasons, release in dry seasons

 Pumped-storage hydropower: provides peak-load supply, harnessing water which is

cycled between a lower and upper reservoir by pumps which use surplus energy from the
system at times of low demand. When electricity demand is high, water is released back to
the lower reservoir through turbines to produce electricity.

 A large storage "battery"

 Upper and lower reservoirs
 Pump/generating unit
 Reversible pump turbine
 Motor/generator
 Consumer of energy
 Cycle efficiency 70-85%
 Benefits
 Generating peak power at high cost
 Pumping off peak at low cost
 Enhancement to a power system
 Rapid and flexible response to system changes
 Allows base load of thermal plants

 Hydromatrix : Hydromatrix is a new innovative concept of hydraulic energy generation,

combining the advantages of proven technology and low cost installation, which is easily
integrated into existing dam structures or weirs. Projects that are not economically feasible with
conventional turbine-generator designs can now be developed profitably by using the
Hydromatrix approach.
  A special type configuration

 Solution for low head sites

 Many small unit instead of conventional

 It is not a typical small hydro

 Applications : navigation dams, irrigation dams, intake towers, shiplocks

IV. PLANT CONFIGURATION

 Surface plant
 Separate from the dam
 Foot of the dam, separate
 Integral part of dam
 Underground plant
 Higher heads
 Rock excavation
 Tunnel boring
 Dam
The dam is the most important component of hydroelectric power plant. The dam is built on a
large river that has abundant quantity of water throughout the year. It should be built at a
location where the height of the river is sufficient to get the maximum possible potential
energy from water.
 Water Reservoir
The water reservoir is the place behind the dam where water is stored. The water in the
reservoir is located higher than the rest of the dam structure. The height of water in the
reservoir decides how much potential energy the water possesses. The higher the height of
water, the more its potential energy. The high position of water in the reservoir also enables it
to move downwards effortlessly.
The height of water in the reservoir is higher than the natural height of water flowing in the
river, so it is considered to have an altered equilibrium. This also helps to increase the overall
potential energy of water, which helps ultimately produce more electricity in the power
generation unit.
 Intake or Control Gates
These are the gates built on the inside of the dam. The water from reservoir is released and
controlled through these gates. These are called inlet gates because water enters the power
generation unit through these gates. When the control gates are opened the water flows due to
gravity through the penstock and towards the turbines. The water flowing through the gates
possesses potential as well as kinetic energy.
 The Penstock
The penstock is the long pipe or the shaft that carries the water flowing from the reservoir
towards the power generation unit, comprised of the turbines and generator. The water in the
penstock possesses kinetic energy due to its motion and potential energy due to its height.
The amount of water flowing through the penstock is controlled by the control gates.
 Water Turbines
Water flowing from the penstock is allowed to enter the power generation unit, which houses
the turbine and the generator. When water falls on the blades of the turbine the kinetic and
potential energy of water is converted into the rotational motion of the blades of the turbine.
The rotating blades causes the shaft of the turbine to also rotate. The turbine shaft is enclosed
inside the generator. In most hydroelectric power plants there is more than one power
generation unit. There is large difference in height between the level of turbine and level of
water in the reservoir. This difference in height, also known as the head of water, decides the
total amount of power that can be generated in the hydroelectric power plant.
There are various types of water turbines such as Kaplan turbine, Francis turbine, Pelton
wheels etc. The type of turbine used in the hydroelectric power plant depends on the height of
the reservoir, quantity of water and the total power generation capacity.
 Generators
It is in the generator where the electricity is produced. The shaft of the water turbine rotates
in the generator, which produces alternating current in the coils of the generator. It is the
rotation of the shaft inside the generator that produces magnetic field which is converted into
electricity by electromagnetic field induction. Hence the rotation of the shaft of the turbine is
crucial for the production of electricity and this is achieved by the kinetic and potential
energy of water. Thus in hydroelectricity power plants potential energy of water is converted
into electricity.

 Switchgears
Switchgear is a combination of electrically disconnect switches, fuses or circuit breakers used
to control, protect and isolate electrical equipment. Switchgears are used to de-energize
equipment to allow work to be done and to clear faults downstream. Mainly consists of the
high voltage switching equipment which includes : generator transformers, current
transformers, circuit breakers, voltage transformers, isolators and lightening arrestors.
VI. POWER STATION EQUIPMENT

POWER STATION
EQUIPMENT

OPTIONAL
MAIN AUXILIARY
AUXILIARY
EQUIPMENT EQUIPMENT
EQUIPMENT

SCADA system turbine BFV or SV

remote control
gearbox UCB and LT panel
system

generator governor

transformer OPU

switch gear excitation unit

cooling water
system

dewatering and
drainage system

auxiliary AC and
DC system
TURBINES
A turbine is a mechanical device which extracts energy from a moving fluid and converts it into
useful work. The turbines are basically used to produce electricity.

I. MAIN PARTS OF TURBINE

The main parts of a turbine are

1. Nozzle: It guides the steam to flow in designed direction and velocity.

2. Runner: it is the rotating part of the turbine and blades are attached to the runner.

3. Blades: It is that part of the turbine on which the fast moving fluid strikes and rotates the runner.

4. Casing: It is the outer air tight covering of the turbine which contains the runner and blades. It
protects the internal parts of the turbine.

II. WORING PRINCIPLE OF A TURBINE

 A fast moving fluid (it may be water, gas, steam or wind) is made to strike on the blades of
the turbine.

 As the fluid strikes the blades, it rotates the runner. Here the energy of the moving fluid is
converted into rotational energy.

 A generator is coupled with the shaft of the turbine. With the rotation of the runner of the
turbine, the shaft of the generator also rotates. The generator converts the mechanical energy
of the runner into electrical energy.

Hydraulic Turbines transfer the energy from a flowing fluid to a rotating shaft. A turbine is
something that rotates or spins. Hydraulic Turbines have a row of blades fitted to the rotating shaft or
a rotating plate. Flowing liquid, mostly water, when pass through the Hydraulic Turbine it strikes the
blades of the turbine and makes the shaft rotate. While flowing through the Hydraulic Turbine the
velocity and pressure of the liquid reduce, these result in the development of torque and rotation of
the turbine shaft. There are different forms of Hydraulic Turbines in use depending on the
operational requirements. For every specific use a particular type of Hydraulic Turbine provides the
optimum output.
III. CLASSIFICATION OF TURBINES
 Type of action of the runner
 Impulse turbine
 Reaction turbine
 Direction of flow through runner
 Tangential flow
 Radial flow
 Axial flow
 Head at inlet of turbine
 High head
 Medium head
 Low head
 According to specific speed
 High
 Medium
 Low
Impulse turbine
The impulse turbine generally uses the velocity of the water to move the runner and discharges to
atmospheric pressure. The water stream hits each bucket on the runner. There is no suction on the
down side of the turbine, and the water flows out the bottom of the turbine housing after hitting the
runner. An impulse turbine is generally suitable for high head, low flow applications. In an impulse
turbine, the fluid is forced to hit the turbine at high speed. They are best suited to applications with a
high head but a low volume flow rate such as fast flowing shallow water courses though it is used in
a wide range of situations with heads from as low as 15 metres up to almost 2000 metres.
 Pelton turbine : the pelton turbine is an example of an impulse turbine. High pressure
heads give rise to very fast water jets impinging in the blades resulting in very high rotational
speeds in the turbine. The split bucket pairs divide the water flow ensuring balanced axial
forces on the turbine runner. Pelton wheels are ideal for low power installations with power
outputs of 10kW or less but they have also been used in installations with power output of up
to 200MW. Efficiencies up to 95% are possible.
Reaction turbine
A reaction turbine develops power from the combined action of pressure and moving water. The
runner is placed directly in the water stream flowing over the blades rather than striking each
individually. Reaction turbines are generally used for sites with lower head and higher flows than
compared with the impulse turbines.
 Francis turbine : the Francis turbine is an example of a reaction turbine. Water flow enters
in a radial direction of the axis and exits in the direction of the axis. Large scale turbines used
 in dams are capable of delivering over 500MW of power from a head of water of around 100
metres with efficiencies of up to 95%.
 Propeller /Kaplan turbine : the propeller turbine, is another example of a reaction turbine.
Designed to work fully submerged, it is similar in form to a ship's propeller and is the most
suitable design for low head water sources with a high flow rate such as those in slow
running rivers. Designs are optimised for a particular flow rate and efficiencies drop of
rapidly if the flow rate falls below the design rating. The Kaplan version has variable pitch
vanes to enable it to work efficiently over a range of flow rates.

IV. PELTON TURBINE

It is a type of tangential flow impulse turbine used to generate electricity in the hydroelectric power
plant. The Pelton turbine was discovered by the American engineer L.A. Pelton

 The energy available at the inlet of the Pelton turbine is only kinetic energy. The pressure at
the inlet and outlet of the turbine is atmospheric pressure.
 This type of turbine is used for high head.

Main Parts of Pelton Turbine

The various parts of the Pelton turbine are

1. Nozzle and Flow Regulating Arrangement (Spear)

 Nozzle is used to increase the kinetic energy of the water that is going to strike the buckets or
vanes attached to the runner.
 The quantity of water that strikes the buckets is controlled by spear. The spear is installed
inside the nozzle and regulates the flow of water that is going to strike on the vanes of the
runner. A nozzle containing spear is shown in the figure given below.
 The spear is a conical needle present in the nozzle. It is operated by a hand wheel or
automatically in an axial direction.
 When the spear is move backward the rate of flow of water increases and when it is pushed
forward the rate of flow of water decreases.

2. Runner and Buckets

The runner with buckets is shown in the figure given below.

 Runner is a rotating part of the turbine. It is a circular disc on the periphery of which a
number of buckets evenly spaced are fixed.
 The buckets are made by two hemispherical bowl joined together. Each buckets have a wall
in between two hemispherical bowl called splitter.
 The splitter splits the jet of water striking the buckets into two equal parts and the jet of water
comes out at the outer edge of the bucket.
 The buckets are designed in such a way that the jet of water strike the buckets, deflected
through 160 degree to 170 degree.
 The buckets of the Pelton turbine are made up of cast iron, cast steel bronze or stainless steel.
3. Casing:
The outer covering of the Pelton turbine is called casing. The Pelton turbine with the casing is shown
in the figure given below.

 It prevents the splashing of the water and helps to discharge the water to the trail race. It also
acts as a safeguard in the case of any accident occurs.
 Cast iron or fabricated steel plates are used to make the casing of the Pelton Turbine.

4. Breaking jet

 When the jet of water is completely closed by pushing the spear in forward direction than the
amount of water striking the runner becomes zero. But still the runner keeps moving due to
the inertia of the runner.
 In order to stop the runner in the shortest possible time a small nozzle is provided which
directs the jet of water at the back of the vanes. This jet of water used to stop the runner of the
Pelton turbine is called breaking jet.

Working of Pelton Turbine

 The water stored at high head is made to flow through the penstock and reaches the nozzle of
the Pelton turbine.
 The nozzle increases the K.E. of the water and directs the water in the form of jet.
 The jet of water from the nozzle strikes the buckets (vanes) of the runner. This made the
runner to rotate at very high speed.
 The quantity of water striking the vanes or buckets is controlled by the spear present inside
the nozzle.
 The generator is attached to the shaft of the runner which converts the mechanical energy (
i.e. rotational energy) of the runner into electrical energy.
 This is the working of the Pelton turbine.

Application
Pelton turbine is used in the hydroelectric power plant where the water available at high head i.e. 150
m to 2000 m or even more. In hydroelectric power plant it is used to drive the generator attached to it
and the generator generates the mechanical energy of the turbine into electrical energy.

V. FRANCIS TURBINE
The Francis turbine is a type of water turbine that was developed by James B. Francis in Lowell,
Massachusetts.[1] It is an inward-flow reaction turbine that combines radial and axial flow concepts.
Francis turbines are the most common water turbine in use today. They operate in a water head from
40 to 600 m (130 to 2,000 ft) and are primarily used for electrical power production. The electric
generators that most often use this type of turbine have a power output that generally ranges from
just a few kilowatts up to 800 MW, though mini-hydro installations may be lower.
Main Parts of Francis Turbine
A Francis turbine consists of the following main parts:
Spiral casing: The spiral casing around the runner of the turbine is known as the volute casing or
scroll case. Throughout its length, it has numerous openings at regular intervals to allow the working
fluid to impinge on the blades of the runner. These openings convert the pressure energy of the fluid
into momentum energy just before the fluid impinges on the blades. This maintains a constant flow
rate despite the fact that numerous openings have been provided for the fluid to enter the blades, as
the cross-sectional area of this casing decreases uniformly along the circumference.
Guide or stay vanes: The primary function of the guide or stay vanes is to convert the pressure
energy of the fluid into the momentum energy. It also serves to direct the flow at design angles to the
runner blades.
Runner blades: Runner blades are the heart of any turbine. These are the centres where the fluid
strikes and the tangential force of the impact causes the shaft of the turbine to rotate, producing
torque. Close attention in design of blade angles at inlet and outlet is necessary, as these are major
parameters affecting power production.
Draft tube: The draft tube is a conduit that connects the runner exit to the tail race where the water
is discharged from the turbine. Its primary function is to reduce the velocity of discharged water to
minimize the loss of kinetic energy at the outlet. This permits the turbine to be set above the tail
water without appreciable drop of available head.
Working of Francis Turbine
Francis Turbines are generally installed with their axis vertical. Water with high head (pressure)
enters the turbine through the spiral casing surrounding the guide vanes. The water looses a part of
its pressure in the volute (spiral casing) to maintain its speed. Then water passes through guide vanes
where it is directed to strike the blades on the runner at optimum angles. As the water flows through
the runner its pressure and angular momentum reduces. This reduction imparts reaction on the runner
and power is transferred to the turbine shaft.
If the turbine is operating at the design conditions the water leaves the runner in axial direction.
Water exits the turbine through the draft tube, which acts as a diffuser and reduces the exit velocity
of the flow to recover maximum energy from the flowing water.

Application
• Francis type units cover a head range from 40 to 600 m (130 to 2,000 ft).

• Its efficiency decreases as flow decreases.

• They may also be used for pumped storage, where a reservoir is filled by the turbine (acting as a
pump) driven by the generator acting as a large electrical motor during periods of low power
demand.

VI. KAPLAN TURBINE

Kaplan Turbine is an Axial Flow Reaction Turbine. For Axial Flow Turbines, the water flows
through the runner along the direction parallel to the axis of rotation of the runner. Reaction Turbine
means that the water at the inlet of the Turbine possesses Kinetic Energy as well as Pressure Energy.
For Axial Flow Reaction Turbine, the shaft of the turbine is vertical. The lower end of the shaft is
made larger and is called ‘Hub’ or ‘Boss’. The vanes are fixed on the hub and hence Hub acts as
runner for axial flow turbine. The vanes on the Hub are adjustable for Kaplan Turbine. The specific
speed (Ns) of Kaplan turbine ranges from 300 to 600 and is a low head turbine.

Parts of Kaplan turbine

Scroll casing: The water from the penstocks enters the scroll casing and then moves to the guide
vanes. From the guide vanes, the water turns through 90° and flows axially through the runner.

Guide Vane Mechanism: The Guide Vanes are fixed on the Hub.

Hub: For Kaplan Turbine, the shaft of the turbine is vertical. The lower end of the shaft is made
larger and is called ‘Hub’ or ‘Boss’. The vanes are fixed on the hub and hence Hub acts as runner for
axial flow turbine.

Draft Tube: The pressure at the exit of the runner of Reaction Turbine is generally less than
atmospheric pressure. The water at exit cannot be directly discharged to the tail race. A tube or pipe
of gradually increasing area is used for discharging water from the exit of turbine to the tail race.
This tube of increasing area is called Draft Tube. One end of the tube is connected to the outlet of
runner while the other end is sub-merged below the level of water in the tail-race.

Applications
• Kaplan turbines are widely used throughout the world for electrical power production. They cover
the lowest head hydro sites and are especially suited for high flow conditions.

• Inexpensive micro turbines on the Kaplan turbine model are manufactured for individual power
production with as little as two feet of head.

• Large Kaplan turbines are individually designed for each site to operate at the highest possible
efficiency, typically over 90%. They are very expensive to design, manufacture and install, but
operate for decades.
Generators
The electrical machine can be defined as a device that converts electrical energy into mechanical
energy or mechanical energy into electrical energy. An electrical generator can be defined as an
electrical machine that converts mechanical energy into electrical energy. An electrical generator
typically consists of two parts; stator and rotor.
I. SYNCHRONOUS GENERATOR
The rotating and stationary parts of an electrical machine can be called as rotor and stator
respectively. The rotor or stator of electrical machines acts as a power-producing component and is
called as an armature. The electromagnets or permanent magnets mounted on the stator or rotor are
used to provide magnetic field of an electrical machine. The generator in which permanent magnet is
used instead of coil to provide excitation field is termed as permanent magnet synchronous generator
or also simply called as synchronous generator.

II. CONSTRUCTION
In general, synchronous generator consists of two parts rotor and stator. The rotor part consists of
field poles and stator part consists of armature conductors. The rotation of field poles in the presence
of armature conductors induces an alternating voltage which results in electrical power generation.

The speed of field poles is synchronous speed and is given by

Where, ‘f’ indicates alternating current frequency and ‘P’ indicates number of poles.

III. WORKING PRINCIPLE

Faraday's law
First law of electromagnetic induction states that whenever a conductor is placed in a varying
magnetic field, emf is induced which is called induced emf, if the conductor circuit is closed, current
is also induced known as induced current.

Second law of electromagnetic induction states that the induced emf is equal to the rate of change of
flux linkages.

Lenz's Law
Lenz's law states that when an emf is generated by a change in magnetic flux according to Faraday's
Law, the polarity of the induced emf is such, that it produces an current that's magnetic field opposes
the change which produces it.

The principle of operation of synchronous generator is electromagnetic induction. If there exists a

relative motion between the flux and conductors, then an emf is induced in the conductors. To
understand the synchronous generator working principle, let us consider two opposite magnetic poles
in between them a rectangular coil or turn is placed as shown in the below figure.

If the rectangular turn rotates in clockwise direction against axis a-b as shown in the below figure,
then after completing 90 degrees rotation the conductor sides AB and CD comes in front of the S-
pole and N-pole respectively. Thus, now we can say that the conductor tangential motion is
perpendicular to magnetic flux lines from north to south pole.

So, here rate of flux cutting by the conductor is maximum and induces current in the conductor, the
direction of the induced current can be determined using Fleming’s right hand rule. Thus, we can say
that current will pass from A to B and from C to D. If the conductor is rotated in a clockwise
direction for another 90 degrees, then it will come to a vertical position as shown in the below figure.
Now, the position of conductor and magnetic flux lines are parallel to each other and thus, no flux is
cutting and no current will be induced in the conductor. Then, while the conductor rotates from
clockwise for another 90 degrees, then rectangular turn comes to a horizontal position as shown in
the below figure. Such that, the conductors AB and CD are under the N-pole and S-pole respectively.
By applying Fleming’s right hand rule, current induces in conductor AB from point B to A and
current induces in a conductor CD from point D to C.

So, the direction of current can be indicated as A – D – C – B and direction of current for the
previous horizontal position of rectangular turn is A – B – C – D. If the turn is again rotated towards
vertical position, then the induced current again reduces to zero. Thus, for one complete revolution of
rectangular turn the current in the conductor reaches to maximum & reduces to zero and then in the
opposite direction it reaches to maximum & again reaches to zero. Hence, one complete revolution
of rectangular turn produces one full sine wave of current induced in the conductor which can be
termed as the generation of alternating current by rotating a turn inside a magnetic field.
Now, if we consider a practical synchronous generator, then field magnets rotate between the
stationary armature conductors. The synchronous generator rotor and shaft or turbine blades are
mechanically coupled to each other and rotates at synchronous speed. Thus, the magnetic flux cutting
produces an induced emf which causes the current flow in armature conductors. Thus, for each
winding the current flows in one direction for the first half cycle and current flows in the other
direction for the second half cycle with a time lag of 120 degrees (as they displaced by 120 degrees).
Hence, the output power of synchronous generator can be shown as below figure.
IV. TYPES OF GENERATORS

 Hydro generators
 Turbo generators
 Engine driven generators

V. BASIC COMPONENTS
 Rotor
 Stator
 Excitation system
 Bearings
 Cooling system
 Brakes and jacks

VI. ROTOR

Types of generators depending on rotor construction

 Salient pole machines : (distributed winding in slots/winding end caps to support the
rotor end winding) These type of machines have salient pole or projecting poles with
concentrated field windings. This type of construction is for the machines which are driven
by hydraulic turbines or diesel engines.
 Non salient pole or cylindrical rotor or round rotor machines : (concentrated
winding/pole end plates to support the pole stampings) These machines are having cylindrical
smooth rotor construction with distributed field winding in slots. This type of rotor
construction is employed for machine driven by steam turbines.

Types of generators depending on shaft orientation

 Vertical axis
 Horizontal axis
Construction
 Rotor shaft
 Bearings
 Slip rings
 Rotor field windings
 Internal cooling fan
 Finger poles
VII. STATOR
Stator Construction
 Stator core
 Stator winding
 Stator frame
 Pressing fingers
 Pressing plate or clamping plates
 Ventilating ducts (for cooling)
 Bracing rings
POLE SHOP
The pole assembly has two parts, viz. the pole coil and the pole body

 POLE COIL
I. BRAZING
Induction brazing is a process in which two or more materials are joined together by a filler metal
that has a lower melting point than the base materials using induction heating. In induction heating,
usually ferrous materials are heated rapidly from the electromagnetic field that is created by the
alternating current from an induction coil. It has several advantages which are listed as follows:
i. Ideal for serial production due to precise process repeatability.
ii. Better Joint Quality- Induction heating produces clean, leak proof joints by preventing the
filler from flowing in areas that it shouldn't flow. This ability to create clean and controllable
joints is one of the reasons that induction brazing is being used extensively for high precision,
high reliability applications.
iii. Minimal wear of inductors – the heating process by induction brazing does not require any
contact between the inductor and the workpiece..
iv. Maximum safety of induction brazing – the induction brazing process involves no fuel gas
and no open flame.
v. Selective heating directly targeted at the desired area of the workpiece. Induction heating can
be targeted to provide heat to very small areas within tight production tolerances. Only those
areas of the part within close proximity to the joint are heated; the rest of the part is not
affected. Since there is no direct contact with the part, there is no opportunity for breakage.
The life of the fixturing is substantially increased because problems due to repeated exposure
to heat (such as distortion and metal fatigue) are eliminated. This advantage becomes
particularly important with high temperature brazing processes. With efficient coil design,
careful fixturing and consistent part placement, it is possible to simultaneously provide heat
in different areas of the same part.
vi. Minimum energy Requirement- The induction brazing process can be restarted immediately,
without delay or warm-up period.
vii. Easy and safe application of induction brazing – the heat input for induction brazing can be
controlled very easily and with high precision.
viii. Brazing with induction reduces both oxidation and costly cleaning requirements, especially
when a rapid cool down cycle is used. Reduction of porosity and weak brazing joints, due to
precise and reliable process control, such as power and time.
ix. Reduction of cold brazing joints – the heat input during induction brazing occurs directly,
without negatively affecting the base material. (reproducible)
x. Fast heating cycles-Because the induction heating cycle is very short in comparison to flame
brazing, more parts can be processed in the same amount of time, and less heat is released to
the surrounding environment. “An induction brazing system quickly delivers highly localized
heat to minimize part warpage and distortion. Brazing in a controlled vacuum or in an inert
 protective atmosphere can significantly improve overall part quality and eliminate costly part
cleaning procedures”

All the joints are brazed by a 45kW induction brazing machine. The brazing foil used is a
0.2mm thick foil of silver (18%) and phosphorous (36%) alloy of copper. For joints, the
brazing temperature varies from 640℃ to 700℃. However, the pole connections are to be
cooled after brazing and the maximum temperature must not exceed 250℃ in this area.

II. PRESSING AND CLEANING

All the joints are plained after brazing. The excess material that protrudes out of the inter
turns of the coil at the brazing points is pressed using a hydraulic copper joint pressing
machine. This flattens, strengthens and cleans the brazed joint.

III. WINDING

Each interturn has two layers of 0.15mm thickness prenambi paper which is epoxy-resin
coated, to provide insulation between each turn.

IV. CONSOLIDATION

Consolidation processes consist of the assembly of smaller objects into a single product in
order to achieve a desired geometry, structure, or property. These processes rely on the
application of mechanical, chemical, or thermal energy to effect consolidation and achieve
bonding between objects. Interaction between the material and the energy that produces the
consolidation is a key feature of the process. This interaction can be either beneficial or
detrimental to the final product. In some cases, the consolidation energy enhances the
structure or properties of the material and is an integral part of the process.
Consolidation processes are employed throughout the manufacturing sequence, from the
initial production of the raw material to modification of the final assembly.

The complete pole coil is arranged, pressed and heated in a consolidation machine at a
temperature of 170℃ for two hours. The pole coil is then shaped in the consolidation
machine itself. The shape of the pole coil is decided according to the number of poles of the
generator. The pole coil has slight curve if the number of poles is less, however, in case of
machines having a large number of poles, the pole coils are straight. The temperature at
different parts of the coil is measured during consolidation. The completion of this process is
marked by the change of colour of the pole coil copper to golden.
V. ELECTRICAL TESTING

A. SURGE COMPARISON TEST

The Surge Comparison tester checks the strength of ground insulation that consists of
enamelled insulation. It detects the insulation failures such as turn-to-turn shorts,
layer-to-layer shorts, coil-to-coil shorts, winding-to-winding shorts, and phase-to-
phase shorts. Open circuit and ground detection are other benefits of surge
testing. Other problems found include wrong internal connections and wrong turn
counts. Weak turn to turn insulation is the start of most winding failures. Because it is
the only test that can find weak insulation at elevated voltages, the surge test is
important for generator reliability and maintenance programs, for diagnosing
problems and for quality control. It is an especially powerful tool in combination with
Partial Discharge measurements. Surge tests are done on individual coils, stators,
wound rotors and fully assembled motors and generators without the need to turn the
rotor.

The Surge tester uses the principle of impedance balance to test the quality of
electrical windings. The Surge tester works as a capacitive-discharge system. A
capacitor is charged with high voltage and then discharged into the winding, through a
solid state assembly. This sequence is repeated thus stressing the insulation of the
winding with high voltage pulses.
The resulting voltage decay pattern of two winding is then displayed on the CRT. The
waveform pattern will be perfectly superimposed for good windings but in case of a
defective winding a double wave pattern will appear on the screen as one wave
pattern from the good winding plus the erratic pattern from the faulty winding.

B. IMPEDANCE TEST

This testing addresses the rapidly expanding development and deployment of

increasingly sophisticated electronic equipment, which places greater demands on
instrumentation and testing capabilities. The impedance test is usually carried out to
check the impedance or the overall resistance of the coil by supplying a voltage 2-3%
greater than the rated voltage of the generator to be designed.
  POLE BODY
The pole body has four parts:

i. Pole end plates- These are made of chromium steel. Chromium improves the corrosion
resistance of the steel.
ii. Pole sheet- These are silicon-coated mild steel thin sheets. Silicon provides insulation in
between sheets.
iii. Pole pressing bolt
iv. Nut

The operation is known as pole body stacking on straight edge. The pole end plates and sheets,
along with the pressing bolts are compressed by applying a pressure of 5000 psi using the power
pack hydraulic machine. Different tests are carried out to verify the straightness, length,
perpendicularity and compactness of the pole body according to the drawings. Metal arc welding
is done to make the pressing bolt in line with the pole body. The damper segments are brazed
using a dobble or guide pin. The damper brazing is done to insert and lock the damping rods in
pole body. Here, it is noted that thin pole sheets are used to reduce eddy current losses.

 POLE ASSEMBLY
The pole body along with the pole coil is placed on the workbench, with the insulation frame placed
on the shaft side. A glass cord is arranged in the gap between the pole body and insulation frame.
The glass cord is fire proof, doesn’t melt on welding and also prevents dust to enter inside the pole
body. The corner insulation is done using aramid paper. The pole pressing frame is welded on the
pole body by metal arc welding, manually. The filler rods are pre-heated before welding to prevent
moisture in flux. Lastly, the complete pole assembly is I-varnished and painted. The varnish is 35%
thinner in composition and has 40 micron thickness.

Then, the pole assembly is subjected to several tests which are listed below.

A. HV or High Voltage Test

B. Megger Insulation Resistance Test
C. Surge Comparison Test
COIL AND BAR SHOP
This shop involves the manufacturing of coils and bars for the windings of stator and rotor of the
hydro and turbo generators. The following operations are performed in this shop:

I. ROEBELLING

SKIN EFFECT is the tendency of an alternating electric current (AC) to become distributed within
a conductor such that the current density is largest near the surface of the conductor, and decreases
with greater depths in the conductor. The electric current flows mainly at the "skin" of the conductor,
between the outer surface and a level called the skin depth. The skin effect causes the
effective resistance of the conductor to increase at higher frequencies where the skin depth is smaller,
thus reducing the effective cross-section of the conductor. The skin effect is due to opposing eddy
currents induced by the changing magnetic field resulting from the alternating current. Magnetic flux
is higher near the rotor side of the bar in a generator than at the bottom of the bar (i.e., farthest from
the rotor. Consequently, if the strands in a Roebel coil were always in the same position within the
bar, throughout the length of the bar, the strands closer to the rotor would have a greater induced
voltage on them than strands furthest from the rotor. If strands are connected together that have a
potential difference induced by the different flux levels, then, by Ohm’s Law, an axial current will be
forced to flow up and down the bar. Since the resistance of the copper is low, the circulating current
flow will be substantial. This will increase the I2R loss, which reduces efficiency and increases the
temperature of the copper.

Transpositions occur only in form-wound machines. Multi-turn coils may have what may be called
an internal transposition of the copper conductors often called an inverted or twisted turn). Roebel
bars (half-turn coils) always have a transposition. Usually, Extra insulation is needed in the vicinity
of the transposition to ensure that strand shorts do not occur.

In a Roebel transposition, each copper strand is placed into every possible position in the bar as the
strand moves along the length of the bar. That is. a strand that is initially in the top-left position after
several centimeters along the bar will be shifted one position lower on the left. The same strand will
then be forced another position lower (i.e., two strand positions from the top) a few centimeters
further along the bar. About half way along the bar, the strand will be in the bottom position on the
left. Then the strand is shifted from the left side of the conductor stack to the right side, and
gradually moves up to the top right position ri the other half of the bar, Eventually it reaches its
original position. This is called a 360° transposition. If this 360° transposition is done in the stator
core, where the magnetic flux is the highest, then a single strand will have been in each radial
position for the same distance along the slot. The total induced voltage on this strand will then be the
same as the induced voltage on all the other strands that were transposed. Thus, one can safely
connect all the strands together at both ends of the bar and not give rise to axial circulating currents.

Transposing can also occur in the end-winding, since stray magnetic fields arc present there. The
purpose of the transposition is to improve stator winding efficiency and reduce operating
temperature. The mechanical process of shifting strands from one position to another is called
Roebelling.
The Roebelling station has a PLC (Programmable Logic Controller) to cut the raw copper wires and
clean them at the ends for a defined length. This raw copper can be either enamel plus insulation, or
may be with glass coating (for stronger insulation). A number of copper wires are placed on the
stagger board and are bent or form S on passing through the hydraulic press. Then they placed on the
crossover wedge, with bonding material EPTH and compression zip, and transposed as explained
above. Epoxy sheets are used for insulation after roebel bars are formed.

II. CONSOLIDATION : HEATING AND PRESSING

This process is carried out in a consolidation machine equipped with hydraulic pressure cylinders
and a vacuum cleaner. The number of cylinders to be used is decided according to the length of the
bars. The bars are subjected to a 250 bar vertical and horizontal pressure each at a temperature of
160℃. The heating cycle time period is 1.5 hours and cooling for 0.5 hours. Vacuum cleaner is
frequently used here, to remove dust particles. A set of two bars are bonded with involute bonding
material. This strengthens the bars, thus making them more durable. After consolidation, the
following tests are carried out.

A. Strand Test: This is carried out to check the insulation between the different conductors or
strands of the consolidated bar. The bar is supplied with 300V AC voltage.
B. Dimensional Check: In this test, the required dimension of the bars is verified, as when
heated the copper may have thermally expanded and hence, exceeded the desired length.

III. FORMING AND BENDING

Bending of sheets and plates is widely used in forming parts such as corrugations, flanges, etc.
Bending is a forming operation in which a sheet metal is subjected to bending stress thereby a flat
straight sheet is made into a curved sheet. The sheet gets plastically deformed without change in
thickness. Die and punch are used for bending. If a v shaped die and punch are used, the bending is
called v-bending. If the sheet is bent on the edge using a wiping die it is called edge bending. In this
process, one end of the sheet is held like a cantilever using a pressure pad and the other end is
deformed by a punch which moves vertically down, bending the sheet. Usually, edge bending is done
in order to obtain an angle of 90°.

During bending of a strip, the material outward of the neutral axis is subjected to tensile stress.
Material inside is subjected to compressive stress. Bend radius R is the radius of curvature of the
bent sheet inside the bending. The neutral axis remains at the center of the thickness of the sheet for
elastic bending. For plastic bending, however, the neutral axis shifts towards the inside of the bend.
The rate of elongation of outer fibers is greater than the rate of contraction of inner fibers. Therefore,
there is a thickness reduction at the bend section.
IV. INDUCTION BRAZING OF END PLATES
The end plates made of copper are induction brazed on the bars so that they can be externally
connected to the rest of the circuit. Here also, the brazing foil used is a 0.2mm thick foil of
silver (18%) and phosphorous (36%) alloy of copper. The brazing temperature goes up to
700℃.

Brazing bonds two pieces of metal by means of a metallic filler that is melted and then
flowed into the space between them by capillary attraction. The filler metal, which is
commonly an alloy of copper, silver, tin and/or zinc with a relatively low melting point, must
fill the space between the two parts being joined, wet the surfaces, and fuse them when it
cools and solidifies. If the braze metal does not flow properly or does not fuse, the integrity
of the joint will be affected. Here, for the brazed joint being an electrical contact, it becomes
very important for the joint to be strong enough and integrated. This problem can usually be
identified with an ultrasonic flaw detector.
Braze joints are typically tested by means of a straight beam test that monitors the amplitude
of the echo from the braze location at the inner surface of the outer metal part. In the case of a
good braze joint at the test point, the metal-to-metal bond will return a relatively small
reflection, while an air gap will return a much larger one. These levels should be established
in each specific case by setting up on reference samples representing known brazed and un-
brazed conditions.

The first waveform shows a reference echo from an un-brazed area of the outer plate, which
has been marked with a gate and set to nearly full screen height. The second waveform shows
the response from a properly brazed point, in which the echo in the gated region drops to a
very low level. It is followed by a larger peak representing the echo from the inside surface of
the inner tube. By observing the amplitude of the echo within the gate, the operator can
determine the joint condition at each test point by comparing the echo amplitude to these
reference levels.

A partial braze within the area of the sound beam due to conditions such as porosity will
typically be represented by a mid-level echo. Note: it is important to remember that very
small discontinuities such as pinholes whose size is a small fraction of the beam diameter will
not be detected through this procedure.
V. INSULATION
Mica composite, epoxy resin and vacuum-pressure impregnation (VPI) provide a robust and
reliable insulation system. The advanced insulation system on all large machines will
typically reward you with years of reliable operation. Andritz’s insulation system is designed
to minimize the effect of localized electrical stress and reduce the effects of partial discharge
while increasing machine life and reliability. Components are selected to ensure reliability of
the system as a whole.
The insulation system can meet applicable standards. All wound stators undergo global
vacuum-pressure impregnation (VPI) treatment. Curing binds the stator components into a
solid and rigid structure with excellent dielectric strength, dimensional stability and
mechanical strength. It also increases the resistance of the winding to thermal shock, moisture
and other contaminants.

Coil Insulation

Once assembled, the coils are inserted into the stator slots and the end connections are brazed
and taped. The coil lock bracing system supports the coils and makes the entire structure
more rigid.
The process of insulation is divided into three stages
1. PRE-INSULATION
In the process of pre-insulation, firstly the surface of the bar is smoothened with a file
and then a layer of white-colored adhesive nomex tape is wrapped over it, which is
followed by a pink-colored f-mica tape. Then, a layer of a black Inner Corona
Protection is added which completes the pre-insulation. Here, it is noted that a copper
strip with tin coating is stuck with a tin paste in between the inner and the outer
insulation tapings to avoid partial discharges. It ensures a direct contact between the
layers of insulation thus, making it short or bringing them at the same potential level.

The partial discharge process occurs in electrical equipment submitted to high voltage
stress. It represents the dielectric breakdown of an electrical insulation and usually has
a sporadic character. Because partial discharge occurs randomly and unexpectedly,
regular partial discharge analysis is highly recommended with any piece of high
voltage equipment. The effects of the partial discharge phenomenon can be very grave
and even lead to a complete breakdown.

2. MAIN INSULATION
The main insulation consists of 6-8 layers of Mica tape; using the automatic
micamation machine.
F-Mica has outstanding flame resistant characteristics (acts as a fire wall) and exhibits
excellent electrical insulating properties at high temperatures. It is widely used for
power & control cables, instrumentation & signalling cables. These cables guarantee a
maximum safety ensuring that strategically installations/equipments (hospitals, oil
rigs, railway tunnels, shopping centres, industrial & military installations…) continue
to operate during a fire or in high temperature environments (up to 950° C natural
mica tape & 1100° C for synthetic mica tape). Due to considerable flexibility and high
 tensile strength, it can be easily applied by high speed (up to 3000 rpm) standard
vertical or longitudinal taping equipment (one or more layers with an overlap of 10-
50% acc. to the applicable norm). It is free of asbestos, halogens and toxic gases.
Composition: High-grade Phlogopite, Muscovite or synthetic mica paper impregnated
with a specially developed high temperature resistant silicone resin and reinforced
with a glass cloth or PE film.

3. FINAL INSULATION
The final insulation consists of the Outer Corona protection which contains graphite
and a cover/shrink tape, which has a special property to shrink during the process of
VPI (Vacuum Pressure Impregnation). Also, an EPG (End Potential Grading) tape,
along with a rubber tape, commonly called as the slide layer, is applied on the bends
of the bars. The complete insulation is then covered with a release film, which
contains holes for the injection of resins during the process of VPI.
GENERATOR ASSEMBLY
 STATOR FRAME
The stator frame is made of welded steel construction and manufactured with thick steel plates to
prevent distortion during operation. Robust and rugged, these frames are designed to withstand the
mass of a stator core, bending stresses and deflections. The frames are designed to minimize
vibrations and noise levels. The frame bore is machined to ensure a uniform air gap between the
rotor and stator, thereby minimizing the unbalanced magnetic pull. These frames are designed to
withstand the extreme stresses due to short circuits.

Each machine is designed to be assembled on a robust concrete foundation or steel base. A minimum
of four lifting points is provided in the generator to facilitate this process. Larger or heavier
machines, which are shipped disassembled, are reassembled over the foundation at the site, as a part
of the field installation process.

The frame is fabricated from structural steel plates to ensure an extremely robust and rigid support
structure. The generator can be designed for open enclosure and totally enclosed water-to-air cooled.
The exciter and rectifier hub are mounted at the non-drive end (NDE) enabling easy access for
maintenance purposes.

 STATOR CORE
The stator core assembly consists of segmented and insulated laminations of cold-rolled low-loss
silicon steel, clamped between substantial side plates. Laminations are stacked up with a controlled
burr in order to ensure minimal losses. Lamination steel is selected based on project requirements.
The core is built inside a structural cage, which is then inserted into the frame and attached through
weldments. Steel I-beam spacers spot welded to low carbon steel laminations form radial ventilation
ducts along the core length. When core building is complete, the whole assembly is clamped under
pressure with studs. The nuts and compression plates are welded in place while maintaining pressure.

 STATOR SHEETS
Silicon steel can be insulated, ventilated depending on design requirement.

The stator sheets are stacked in bundles with a ventilating sheet after each bundle. The ventilating
sheet consists of the pressing fingers which are of double V shape. Spot welding is done to make
ventilated sheets. All the stacked sheets are placed between two pressing frame which compress the
whole arrangement. The process takes place by keeping the whole arrangement on a raised platform
which consists of the pedestals, leveling jack, static device, slot key and slot bar.
  ROTOR

Three types of rotor construction can be utilized in this product line: a laminated spider with
dovetailed poles, a rim spider with bolted poles, or a solid spider with dovetailed poles.

1. Laminated Spider
The rotor spider is made of thin laminations, clamped with axial studs. According to design
needs, there are axial holes to improve the air ventilation through the rotor. The laminated
poles are attached to the spider with dovetails.

2. Solid Spider
The rotor spider and shaft are obtained from a one-piece machined carbon steel forging.
According to design needs, there are axial holes to improve the air ventilation through the
rotor. The laminated poles are fixed on the spider by using dovetails on the pole bottom.

3. Rim Spider

The rim is made of forged steel. The rim is shrunk on to a large web that is attached to the
shaft by means of a hub and a key, then pole bodies are attached to the rim via a number of
radial bolts. Two axial or radial fans (according to design characteristics) are mounted on the
shaft to provide airflow to maintain the machine temperature within the limits specified. The
fans are used to provide double-ended ventilation, helping ensure an even temperature
distribution across the field and stator windings.

 Laminated Poles

The rotor has laminated poles fitted with strip or wire wound field coils and supplied with an
amortisseur winding on the outer pole face. A amortisseur winding is a squirrel cage winding placed
near the surface of the pole faces of a synchronous motor or generator. Its main purpose is to dampen
any speed fluctuations or oscillations that may occur as a result of sudden load changes. It is also
used to accelerate the motor/generator during starting.
VACUUM PRESSURE IMPREGNATION
Vacuum Pressure Impregnation (VPI) is a process that uses vacuum and pressure to seal porous
materials with varnish or resin. The process is used primarily for high-voltage motors and generators
to fill gaps in materials to create a void free insulation in various devices.
It is a process by which a fully wound electric apparatus stator or rotor is completely submerged in a
resin.

Through a combination of dry and wet vacuum and pressure cycles, the resin is assimilated
throughout the insulation system. Once thermally processed, the impregnated windings become a
monolithic and homogenous structure.

A properly globally vacuum pressure impregnated winding will have superior characteristics, which
will support a longer and more maintenance free life span. Industrial electromechanical equipment is
designed for durability to provide reliable function and increased longevity, but age, temperature,
and environmental factors can degrade porous metals over time. The process of impregnation seals
porous materials with varnish or resin, improving the function and longevity of equipment.

 VPI PROCESS
1. Preheating The equipment is placed in an oven that heats it and allows moisture to
evaporate. This helps the resin better penetrate the material.
2. Dry Vacuuming The equipment is removed from the oven and placed into a vacuum
chamber, which removes air and any remaining moisture.
3. Filling The chamber is filled with resin, coating the part and filling in all the gaps and
pores in the piece of equipment.
4. Wet Vacuuming The vacuum levels are reduced and held for a set period of time.
5. Pressure The pressure within the chamber is increased using dry air, nitrogen, or
other gases. This allows for even deeper penetration of the resin.
6. Draining The pressure is then vented, the chamber drained of excess resin, and the
part removed.
7. Curing Finally, the equipment is placed into an oven to cure the resin.

 VPI BENEFITS
In traditional impregnation, varnishes can lose up to 50% of their volume in the curing process. The
reduced volume leads to air pockets and gaps, making it more susceptible to damage and wear. The
vacuum used in a VPI creates a more solid structure that can withstand: Leaks, Cracks, Corrosion
and Moisture.VPI also accommodates longer insulation life and greater heat dissipation. Vacuum
pressure impregnation is a more cost-effective solution as it extends the lifetime of products while
saving energy. The resulting benefits are higher dielectric strength, increased mechanical strength,
greater thermal inductivity, and superior protection against the ingress of water, chemical and
containments.
AUTOMATION TECHNOLOGY
In addition to primary technology, secondary technology is a key competence for a leading supplier
of electromechanical products and services for hydropower stations. In the same way as primary
technology, power station automation is aimed at increasing output and decreasing costs. Whether it
is newly constructed or modernized, each hydropower station requires specially adapted architecture
meeting its specific requirements.

The automatic system reads the information on the equipment status operation, and then activates
commands or controls to optimize the output production. However, this type of system needs
specialized personnel. The operator of the automatic system will have to make necessary changes to
the commands and controls, based on the needs or production demands from time to time. This
approach does not request the full time supervision by an operator. A system for managing,
controlling and protecting the hydroelectric power plant is realized by obtaining information in real
time, by providing powerful local and remote control system and advance protection system. An
automation system consists of:

1. Protection System
2. Control System
3. Measuring System
4. Monitoring System

The automation technology at ANDRITZ HYDRO has three systems, Control, Excitation and
Protection.
Programmable logic controller (PLC) type plant controller combined with PC based SCADA
systems are used for plant control and data acquisition. This makes the system economically viable
thus can be suitable for many small hydro power plants for generation control and automation.
Monitoring, control and data acquisition system (SCADA) can be a part of the PC based digital
governor and generation control equipment. The complete plant control is achieved by a unit control
board (UCB). The functions of an excitation system are
 To provide direct current to the synchronous generator field winding.
 To perform control and protective functions essential for the satisfactory operation of the
power system

ANDRITZ HYDRO excitation systems stand for high availability as well as efficiency, robustness,
high MTBF time, and a lifetime of about 30 years or more. The modular concept provides an optimal
solution for all generator sizes, customers, and plants.

ANDRITZ HYDRO can deliver all technical solutions for excitation systems and fulfil all technical
requirements.
QUALITY ASSURANCE AND SAFETY
ANDRITZ HYDRO actively pursues a thorough risk management to identify and mitigate potential
risks. ANDRITZ applies well-established quality assurance and integrated management systems to
meet customers’ requirements and legal stipulations.
Quality management at ANDRITZ HYDRO means: quality of products, quality of processes, and
quality in safety and environmental issues. With a global quality management system ANDRITZ
HYDRO ensures that its customers all over the world receive high quality, reliable products and
solutions. The safety and efficiency of used machines and equipment has a high focus. ANDRITZ
HYDRO’s quality management system defines fully developed business processes that helps to
execute orders efficiently and ensuring that delivery dates are met.

Safety and environmental protection on installation sites are major objectives at ANDRITZ HYDRO.
Therefore global standards are defined and used as a basis for planning and implementing adequate
safety and environmental measures for each individual project. These measures are aimed at
preventing accidents and ensuring prompt and suitable action in critical situations.

Global standards
The quality management system is implemented at ANDRITZ locations and ensures uniform product
and order execution standards worldwide. Accredited certification partners conduct certification
audits at the locations and confirm effective and consistent implementation of the quality standards
in the certificates issued, e.g. ISO 9001, OHSAS 18001, and ISO 14001.

Quality control (QC) is a procedure or set of procedures intended to ensure that a manufactured
product or performed service adheres to a defined set of quality criteria or meets the requirements of
the client or customer. Andritz Hydro Bhopal has four QC Teams which conduct risk measurements
and assessments at each stage of production,

1. Incoming Inspection is carried out by QC1.

2. In-process Inspection is carried out by QC2.
3. Out-going/Site Inspection or Commissioning Test is carried out by QC3.
4. Supplier Inspection Test is carried out by SQE (Supply Quality Engineering) Team.

Also, there are several online interfaces for quality assurance at Andritz Hydro like:

a. QAP (Quality Assurance Protocol)

b. ITP (Inspection and Test Plant)
c. NCR(Non Conformation Report)
REFERENCE

 www.andritz.com
 www.wikipeia.com
 www.electrical4u.com
 www.elprocus.com