A comprehensive report on the study of

Manufacture & Assembly of Turbo Generator

Project Incharge:
Mr. Satish k. Singh
Submitted By:
BHEL, Haridwar Ajay Jangir
 ACKNOWLEDGEMENT

Engineer is a boon for this modern era because of leaps and bound advancement in
modern technology. So it is a very important to impart a practical knowledge and t
heoretical knowledge. I am very grateful that I got the opportunity to have training
from BHEL, Haridwar. Which is the no.1 industry in India.

Special thanks to Mr. RAJENDRA VERMA for providing me with an opportunity

to undergo training under his able guidance and offering me a very deep knowledg
e of practice aspect of industrial work culture………………

I express my sincere thanks and gratitude to BHEL authorities for allowing me to u

ndergo the training in this prestigious organization. I will always remain indebted t
o them for their constant interest and excellent guidance in my training work, more
over for providing me with an opportunity to work and gain experience.
 CONTENTS
Introduction -1
Coil & insulation manufacturing shop (block-4) -2
Electrical machine block (Block-1) -3
Manufacturing process of turbo generator -4
Introduction to 500MW Turbo Generator -5
Constructional features of stator body -6
Constructional features of core -7
Constructional features of Winding -8
Constructional features of Rotor -9
10-Working principle
11-Cooling system
12-Excitation system
13-Electrical generator protection
14-Conclusion
 INTRODUCTION:-
BHEL is the largest engineering and manufacturing enterprise in India in the energ
y-related/infrastructure sector, today. BHEL was established more than 40 years ag
o, ushering in the indigenous Heavy Electrical Equipment industry in India - a drea
m that has been more than realized with a well-recognized track record of performa
nce. The company has been earning profits continuously since 1971-72 and paying
dividends since 1976-77.BHEL manufactures over 180 products under 30 major pr
oduct groups and caters to core sectors of the Indian Economy viz., Power Generati
on & Transmission, Industry, Transportation, Telecommunication, Renewable Ene
rgy, etc. The wide network of BHEL's 14 manufacturing divisions, four Power Sect
or regional centre, over 100 project sites, eight service centre and 18 regional offic
es, enables the Company to promptly serve its customers and provide them with su
itable products, systems and services. Efficiently and at competitive prices. The hig
h level of quality& reliability of its products is due to the emphasis on design, engi
neering and manufacturing to international standards by acquiring and adapting so
me of the best technologies from leading companies in the world, together with tec
hnologies developed in its own R&D centre,
BHEL has
•Installed equipment for over 90,000 MW of power generation for Utilities, Captiv
e and Industrial users.
•Supplied over 2,25,000 MVA transformer capacity and other equipment operating
in Transmission & Distribution network up to 400 kV (AC & DC).
•Supplied over 25,000 Motors with Drive Control System to Power projects, Petro
 chemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants, etc.
•Supplied Traction electrics and AC/DC locos to power over 12,000 km Railway n
etwork.
•Supplied over one million Valves to Power Plants and other Industries
HEEP
HEEP is also known as heavy electrical equipment plant. In this plant the electrical
devices is manufacture for the production of the Turbo Generator. In HEEP plant
we produce turbo generator, exciter, turbine, AC/DC motor, etc. HEEP had started
the production from January 1967. More than 40% of the electrical energy is gener
ated from the power equipment supplied by BHEL, Haridwar.
 COIL & INSULATION MANUFACTURING AHOP (BLOCK-4):-

BAY-1: Bar winding shop manufacturing of stator winding of generator.

BAY-2: manufacturing of heavy duty generator stator bars with new CNC machi
ne No. 3-464 i.e. Robol bar centre.
BAY-3: Insulation detail shop. Manufacturing of hard insulation & machining of
hard insulation part (Glass textolite) such as packing washer, insulation box, wedge
s etc.
Bar Shop: This shop is meant for manufacturing of stator winding coil of turbo g
enerator.
 Why do we call it bar:-
It is quite difficult of manufacture, handle and wind in the stator slot of the generat
or of higher generation capacity because, of its bigger size and heavy weight. That
is why we make coil in two parts. One part its bottom part of coil called bottom or l
ower bar and other part of coil is called top bar or upper bar.
Turbo – generator: The manufacturing of bars of standard capacity such as:
100MW, 130MW, 150MW, 210/235MW, 210/250MW, 500MW, 600MW
 TYPES OF GENERATOR:
The generator may be classified as based upon the cooling system used in the gene
rators such as: THRI, TARI, THDI, THDD, THDF, THFF, THW.
T= First alphabet significance the type of generator i.e. turbo generator of hydro- g
enerator.
H/A= Second alphabet stands for the cooling media used for the cooling of rotor i.
e. hydrogen gas or air.
R/D/F/I= Third alphabet significance cooling of rotor e.g. radial, indirect forced, di
rect etc.
I/D/F= Last alphabet stands for the type of cooling if stator e.g. indirect cooling,
direct cooling, forced cooling.
W= Cooling media used for cooling of stator coil e.g. water
Resin System
Rich resin or thermo reactive insulation system :
In this type of insulation system the bond content in resin is 35-37%. Th
e raw material are ready to use and required preservation and working on
temperature 20-25C. Its shelf life is one year when kept on temperature 2
0C which could be increased when kept at temperature of 5C.

Poor resin or Micalastic system :

In this type of insulation the bond content in the resin is 5-7% and insulat
ing material is prepared with accelerator treatment. The temperature contr
ol need not required. The insulating material is applied on job and then th
e same is impregnated in the resin.

MANUFACTURING PROCESS OF BARS:

Some points of manufacturing process are in brief as below-
Conductor Cutting:
This process is done by automatic CNC machine. In this process the pre insulated c
opper conductor is cut into number of pieces of required length (length given in dra
wing as per design).Insulation is removed from both side of copper conductor out.
Transposition of conductor:
Transposition means changing/shifting of position of each conductor in active core
(slot) part .After cutting the required number of conductors the conductors are arra
nged in the comb in staggered manner and then bend are given to the conductors w
ith the help of bending die at required distance. Then the conductor are taken out fr
om the comb and die and placed with their end with the line and transposition is ca
rried out. This process is repeated for making another half of the bar which could b
e mirror of the first half. The two halves of the bars are overlapped over each other
and a spacer is placed between the two halves.
Crossover insulation:
The pre insulation of the copper conductor may get damaged due to mechanical be
nding in die during transposition , hence the insulation spacers are provided at the
crossover position of the conductors . A filler material (insulating putty of mouldi
ng mecanite ) is provided along the height of the bars to maintain the rectangular s
hape and to cover the difference of the level of conductors.
Stack Consolidation:
The core part of the bar is pressed in press (closed box) under pressure (varies from
product to product) and temperature of 160`C for a given period. The consolidated
stack is withdrawn from the press and the dimensions are checked.
Inter Strand Short test:
The consolidation bar stack is tested for the short between any two conductor in th
e bar, if found then it has to be rectified.
Forming:
The straight bar is stack is formed as per overhang profile (as per design). The over
hang portion is consolidated after forming.
The straight bar stack is bend at the two end portion as per requirement design.
Brazing of coil lugs:
For water cooled generator bars, the electrical connection contact water box for inl

et and outlet of water are brazed. The water box is also known as contact slew. The

contact slew is brazed with the help of copper aluminium alloy rod. This rod is br

ought to touch to hot contact slew and after melting it fill the spaced, in this manne

r the bar is brazed.

Nitrogen leak test:

The bar is tested for nitrogen flow test, nitrogen leak test and pressure test for give
n duration.
Thermal Shock Test:
In thermal shock test the 23 cycle of hot and cold water are flew throw the bar to e
nsure the thermal expansion and contraction of joints. The temperature of hot water
is about 80`C and the cold water is 30`C. By doing this test if there is any fracture
or voids at the joints are present , then it exposed and easily detected.
Helium leakage test:
This test is performed after the thermal shock test. With the help of this test we can
found very minute leakage if present. In this test the helium gas pipe is connected
at one end and the other end is closed. After this we insert a helium spectrometer to
measure the pressure of the helium gas.
Impregnation and baking:
Thermo reactive system:
In case of reach resin insulation the bar is pressed in closed box in heated con
dition and baked under pressure and temperature as per requirement for a gi
ven period.

Micalastic system :

In case of poor resin system the insulated bars are heated under vacuum and t
he impregnated (dipped) in heated resin so that all the air gap are filled, layer
by layer, with resin. Then extra resin is drained out and the bar are heated and
baked under pressed condition in closed fixture.

VPI Mecalasti System :

The bar already laid in closed fixture and full fixture is impregnated (dipped) i
n resin and then fixture with box is baked under given temperature for given d
uration.

VIP Micalastic system :

The individual (separate) bar is heated in vacuum and impregnated in resin. T

hen bar is taken out and pressed in closed box fixture and then baked at given
temperature for given duration.

Insulation:

The bar is insulated with the given number of layer to built the wall thickness
of insulation subject to the generating voltage of machine.
Finishing:

The baked and dimensionally correct bars are sanded-off to smoothen the edg
es and the surface is calibrated, if required, for the dimension.

Conducting varnish coating:

OCP (Outer Corona Protection) Coating:
The black semiconducting varnish coating is applied on the bar surface on cor
e length.

ECP (End Corona Protection) Coating:

The gray semiconducting varnish is applied on the bend outside corona end of bars
in gradient to prevent from discharge and minimize the end corona.
Testing:
Tan0 Test:
This test is carried out to insure the healthiness of dielectric (Insulation) i.e. dense
or rare and measure the capacitance loss.
H.V. Test:
Each bar is tested momentary at high voltage increased gradually to three times hig
her than rated voltage.
Dispatched for winding:
The bars preserved with polythene sleeves to protect from dust, oil, rain etc are sen
d to block-1 for winding.

ELECTRICAL MACHINE (BLCOK-1):–

INTRODUCTION:-
Block first is design to manufacture Turbo Generators. -1
 The block consist of 4 bays-Bay 1(36*482meters), Bay-2(36*360 meters), -2
and Bay-3 & Bay-4(of size 24*360 meters each).
Testing facilities of turbo generator are available in Bay-2 -3
There is a special test bed area for testing of T.G. of capacity of 500MW unit -4
sizes.
MANUFACTURING PROCESS OF TURBO GENERATOR:-
Fabricated components are received in respective machine sections from-
Fabrications blocks (block-2,5, 6, 8), while castings and forgings are recei
ved from sister unit CFFP and other indigenous and foreign sources for turbo gener
ators. Stampings are received from stampings manufacture block, block-4and coils
bars, insulating details and sheet.
Metal components are received from coils and insulation manufacture and apparatu
s and control gear box (Blok-4).
 TURBO GENERATOR:-

The turbo-generator is common-shaft excitation AC synchronous generator with 3p

hases, 2 poles or with 3 phases, 4 poles.
BHEL-Hyderabad makes turbo generators that have th
e brushless excitation mechanism which has been explained in the NTPC report. B
HEL 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 man
ufacture of ratings up to 1000 MW suitable for thermal power generation, gas base
d and combined cycle power generation as-well-as for diverse industrial applicatio
ns like Paper, Sugar, Cement, Petrochemical, Fertilizers, Rayon Industries, etc.

500MW turbo generator at a glance-

2-pole machine with the following features:-
Direct cooling of stator winding with water. -1
Direct hydrogen cooling for rotor. -2
 Micalastic insulation system. -3
Spring mounted core housing for effective transmission of vibration. -4
Brushless excitation system. -5
Vertical hydrogen coolers. -6
Salient technical data-
Rated output :588MVA, 500MW -1
Terminal voltage :21KV -2
Rated stator current: 16KA -3
Rated frequency :50Hz -4
Rated power factor: 0.85 lag -5
Efficiency : 98.55% -6

Manufacturing process:-
1- Stator-
The stator is assembled as six parts. It is made up of steel with 4.5% of silica. Silic
a decreases hysteresis loss. The sheets are cut at 30 degree angles. The sheets then
are punched with man drill holes, support rod slots and slots for the conductors. Th
is process is called notching and the cutting part as shearing. The sheets are then va
rnished after blanking or smoothening of the surface. This is to increase the insulati
on. A bunch of these sheets are stacked together and compressed onto each other s
o that air gaps are eliminated. These stacks are then assembled with a small air gap
differentiating each stack. This ventilates the machine and keeps it cool. After the a
ssembly of the stator shell, the inside of the slots are varnished. The sheets of the c
ore are varnished with xylor, at a temperature of 30-400 degrees Celsius. It is heate
d, coated then cooled. After the core is assembled , the winding is placed in the stat
or. The winding type depends upon the power required and the current required to
be produced. The core and the winding are separated by an insulation called HGL.
This prevents the shorting of the core and winding .The winding in the front and ba
ck are also separated by this material and they are joined as per the winding require
d (lap or wave) using glass-o-flex, a pink ribbon like material. The windings are in
sulated. These windings are then painted to obtain a the stator, where the power is
generated. The windings are always inserted from the exciter end, one is clockwise
and the other anti-clockwise.

2-The Rotor-
The rotor comprises of following component:
Rotor shaft -1
Rotor winding -2
Rotor wedges and other locating parts for winding -3
Retaining ring -4
Fans -5
Field lead connections -6
 The rotor is carved out with the slots into a cylindrical shape from a large block o
f metal using Lathe heavy machines. The rotor consists of 2 ends –
•The turbine coupling end
•The exciter end

The turbine end has a coupling shaft which is circular in shape and has slots.
The exciter end has an input lead and an output lead which are used to give the roto
r DC input for the excitation of the rotating field.

The ends of each rotor consist of bearings. These bearings are placed so as to supp
ort the shaft. The bearing consists of oil which is used to support a thin film over th
e surface. This lubricates and decreases friction and losses. The bearing has top end
and bottom end and is stationary. The top end is used to supply the oil. After the c
onstruction, the winding is fitted into the slots. The slots and windings are separate
d by HGL or hard glass lamination which insulates the core from the cable. The rot
or is constructed so as to obtain brushless excitation. The complete rotor along wit
h the excitation mechanism is mounted on the shaft and is balanced for synchronou
s speed. For better balancing weight removal is done as that is a better option to ad
ding weight to the system. The rotor ends are provided with induction motor fans
which are used for cooling of the rotor winding. The winding is made up of 99.99
% copper.

WORKING PRINCIPLE:-
One end of the alternator is coupled to the turbine and other end is coupled through
the exciter. The whole assembly is on the shaft. Turbine act as a prime mover, the
permanent magnet of the exciter creates a permanent magnetic field, which is cut b
y the rotor conductors. Making the formation of 3-phase power, this 3-phase power
is fed to the thyristor controlled switches for rectification. The 3-phase power is fe
d to main exciter, after that this 3-phase power is given to the diode wheel so it is
produce the dc power. The dc power is given to the main alternator field without br
ushes and slip ring. Then alternating field is produce by the cut of rotor conductors
making the production of emf by the FARADAY’S LAW.
 Cooling of the Alternator:-
The machine needs to be cooled to avoid damage and for greater life. Heating caus
es insulation failure. Hence, cooling is a very important factor that needs to be take
n care of. For cooling, the stator and rotor are provided with a ventilation to cool it
down. Air gaps are provided throughout the machine. But for very high power mac
hines natural cooling is insufficient so a cooling system is provided. For collection
of hot air, a large chamber is provided. This air is cooled and recycled into the gen
erator. The rotor of the alternator consists of fans powered by induction motors. Th
ey suck in the air and push it through to the cooling chamber. Another method is al
so used which is called hydrogen cooling. Hydrogen acts as ac coolant and the cha
mber is shut completely is filled with hydrogen. Hydrogen cools itself. The chamb
er is emptied each time the machine is stopped.
 TG TEST BED:-
New LSTG [Large Scale Turbo Generator] TEST BED has been put up with indige
nous know –how in record time testing Turbo Generator of rating 500MW and abo
ve up to 1000MW. It caters to the most advanced requirement of testing by employ
ing on line computer for data analysis.

Circuit –Breakers:-
Current interruption in a high-voltage circuit-breaker is obtained by separating two
contacts in a medium, such as SF6, having excellent dielectric and arc quenching p
roperties. After contact separation, current is carried through an arc and is interrupt
ed when this arc is cooled by a gas blast of sufficient intensity. Gas blast applied o
n the arc must be able to cool it rapidly so that gas temperature between the contact
s is reduced from 20,000 K to less than 2000 K in a few hundred microseconds, so
that it is able to withstand the transient recovery voltage that is applied across the c
ontacts after current interruption. Sulphur hexa fluoride is generally used in present
high-voltage circuit-breakers (of rated voltage higher than52 kV)In arc assisted op
ening interruption principle arc energy is used, on the one hand to generate the blas
t by thermal expansion and, on the other hand, to accelerate the moving part of the
circuit breaker when interrupting high currents. The over pressure produced by the
arc energy downstream of the interruption zone is applied on an auxiliary piston lin
ked with the moving part. The resulting force accelerates the moving part, thus incr
easing the energy available for tripping.

With this interrupting principle it is possible, during high-current interruptions, to i

ncrease by about 30% the tripping energy delivered by the operating mechanism an
d to maintain the opening speed independently of the current. It is obviously bette
r suited to circuit-breakers with high breaking currents such as Generator circuit-br
eaker.

COOLING SYSTEM:-
Cooling system is a very important part of the alternator. Mainly two types of cooli
ng process is occur such as-
Radial cooling -1
Axial cooling -2
Since the cooling system is divided three part such as-
Hydrogen cooling -1
Water cooling -2
Air cooling -3

Cooling system is used because dissipating the heat generated by various losses
and to prolong the life of insulating material. In small generator natural cooling
is adequate. In these machines cooling by natural sources is sufficient, but in la
rge generators natural cooling is in sufficient, so in these generator air, water &
hydrogen is done. Force air cooling is used for large machine. In this scheme air
is first passed through cleaning filter and then forced through the machine for c
ooling purpose. Air cooling system is better and necessary in 500MW & 600M
W generator.

EXCITATION SYSTEM:-
Turbo generator is a doubly excited machine. Because it’s field winding is excit
ed by dc source and it’s armature winding is connected to ac source. For dc exci
tation we need use the use of exciter. Hence there are three types of dc excitatio
n-
DC exciter -1
Static excitation -2
Brushless exciter -3
In our BHEL organization brushless exciter is widely use because slip ring and
brushes is absent and it is provide less losses so that it’s efficiency is high so we
use the brushless exciter. The brushless exciter is used for generating the dc fiel
d which is used to fall on alternator of rotor. When the dc field is fall on the roto
r and the rotor is directly connected to the turbine so that the turbine is rotate th
e rotor, the alternating field is generated by the rotor then due to the induction t
he alternating emf is generated in the stator core. These emf is received by the s
tator terminal those are called ac voltage.
The brushless exciter has mainly two parts such has-
Pilot exciter -1
Main exciter -2

In pilot exciter permanent magnet is used, which produce the permanent magnet
ic field. Three phase power from pilot exciter is fed to thyristor controlled brid
ge to main exciter. After rectification the controlled dc output is supplied to stat
ionary field winding of main exciter.
 ELECTRICAL GENERATOR PROTECTION:-
Generator may be endangered by short circuit, ground fault, over voltage, under
excitation and excessive thermal stresses. The following protective equipment i
s recommended such as –

Differential protection -1
Stator ground fault protection -2
Rotor ground fault protection -3
Under excitation protection -4
 Over current protection -5
Load unbalance protection -6
Rise in voltage protection -7
Under frequency protection -8
Reverse power protection -9
10-Over voltage protection

CONCLUSION:-

Bharat heavy electrical limited is the largest engineering and manufacturing ent
erprises of kind in the public sector in India. The sector is an important part in t
urbo generators. The stator is assembled by the laminated sheets. We use the U
NIVERSAL FORM FICTURE type bar which assemble all the straight part and
the over hang at a time. The universal from facture type bar is more flexible an
d its life time more. We use the bar transposition for stator winding which is mo
re advantages. BHEL has acquired the latest technology in the insulation system
, the VACCUM IMPREGINATION system of insulation, which has various ad
vantages like cost reduction with improve quality. Thus designed an manufactur
ed start of turbo generator is used mostly in paper, sugar, cement, petrochemical
, fertilizer, Rayon, industries. The architecture of BHEL, the way various units a
re linked and the way working of whole plant is controlled make the students re
alize that engineering is not just structural description but greater part is plannin
g and management.
It has allowed us and an opportunity to get and exposure imple
mentation of theoretical fundamental.