PREFACE

This training report pertains to four week industrial training that I have undergone at BHEL, Haridwar as a part of curriculum of B.Tech(Electrical Engineering).The purpose of this training is to expose the trainees with practical experience of actual. I learned much from the professional managers and engineers with whom I was placed for training work. Justification cannot be done to whatever I have learnt in four weeks within a few pages but I have still tried my best to cover as much as possible in this report.

ACKNOWLEDGEMENT

Training is one of the important aspects of engineering students carrier. Its basically to strengthen the theoretical concepts. Though this training a student gets acquainted with latest technology and recent developments. Firstly, I convey my sincere thanks to all the employees of BHARAT HEAVY ELECTRICALS LIMITED, HARIDWR. Their love and guidance was omnipotent and incompatible throughout the training period I would like to express my sincere thanks to Mr.P.S.JANGPANGI for valuable suggestions, valuable guidance, support, encouragement and providing necessary information for this project which have been a key to success in the project.

Pradeep saini Final year (ELECTRICAL ENGG)

CONTENTS:
INTRODUCTION BHEL-AN OVERVIEW HEAVY ELECETRICAL EQUIPMENT PLANT(HEEP) BRIEF DISCRIPTION OF ALL MANUFACTURING BLOCKS ELECTRICAL MACHINE BLOCK-1 1. TURBO GENERATOR 2. LARGE SIZE TURBO GENERATOR 3. COMPONENTS OF TURBOGENRATOR STATOR STATOR CORE STATOR WINDING END COVERS ROTOR STEPS IN ROTATING MACHINE 4. VENTILATION AND COOLING SYSTEM 5. EXCITATION SYSTEM 6. TESTING 7. CONCLUSION

BRIGHTENING LIVES, POWERING PROGRESS

INTRODUCTION

BHEL was established more than 50 years ago when its first plant was setup in Bhopal ushering in the indigenous Heavy Electrical Equipment Industry in India. A dream which has been more than realized with a well recognized track record of performance it has been earning profits continuously since 1971-72 and achieved a turnover of Rs 2,658 crore for the year 2007-08, showing a growth of 17 per cent over the previous year. Bharat Heavy Electricals Limited is countrys Navratna company and has earned its place among very prestigious national and international companies. It finds place among the top class companies of the world for manufacture of electrical equipments. BHEL caters to core sectors of the Indian Economy viz., Power Generation's & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, Defense, etc. BHEL has already attained ISO 9000 certification for quality management, and ISO 14001 certification for environment management and OHSAS 18001 certification for Occupational Health and Safety Management Systems. The Company today enjoys national and international presence featuring in the Fortune International -500 and is ranked among the top 10 companies in the world, manufacturing power generation equipment. BHEL is the only PSU among the 12 Indian companies to figure in Forbes Asia Fabulous 50 list. Probably the most significant aspect of BHELs growth has been its diversification .The constant reorientation of the organization to meet the varied needs in time with a philosophy that has led to total development of a total capability from concepts to commissioning not only in the field of energy but also in industry and transportation. In the world power scene BHEL ranks among the top ten manufacturers of power plant equipments not only in spectrum of products and services offered, it is right on top. BHELs technological excellence and turnkey capabilities have won it worldwide recognition. Over 40 countries in world over have placed orders with BHEL covering individual equipment to complete power stations on turnkey basis.

BHEL A Brief Profile:BHEL is the largest engineering and manufacturing enterprise in India in the energy related infrastructure sector today. The wide network of BHEL's 14 manufacturing division, four power Sector regional centers, over 150 project sites, eight service centers and 18 regional offices, enables the Company to promptly serve its customers and provide them with suitable products, systems and services efficiently and at competitive prices. While the company contributes more than 75% of the national grid, interestingly a share of 45% comes from its single unit. And this is none other than BHEL-Hardwar. BHEL has: Installed equipment for over 90,000MW of power generation--- for utilities captive and industrial users. Supplied over 2, 25,000 MVA transformer capacity and other equipment operating in transmission and distribution network up to 400 kV (AC & DC). Supplied over 25,000 motors with drive control systems to power projects, petrochemicals, refineries, steel, aluminum, fertilizers, cement plants etc. Supplied Traction electrics and AC/DC locos to power over 12,000 kms railway network. Supplied over one million valves to power plants and other industries.

BHEL An Overview:BHEL today is the largest Engineering Enterprise of its kind in India with

excellent track record of performance, making profits continuously since 1971-72. BHEL's vision is to become a world-class engineering enterprise, committed to enhancing stakeholder value. The company is striving to give shape to its aspirations and fulfill the expectations of the country to become a global player. BHEL business operations cater to core sectors of Indian Economy like. Power Industry Transportation Transmission Defences etc. The greatest strength of BHEL is its highly skilled and committed 42,600 employees. Every employee is given an equal opportunity to develop himself and grow in his career. Continuous training and retraining, career planning, a positive work culture and participative style of management all these have engendered development of a committed and motivated workforce setting new benchmarks in terms of productivity, quality and responsiveness.

POWER SECTOR
Power generation sector comprises thermal, gas, hydro and nuclear power plant business. BHEL supplied utility sets accounts to 87,646 MW 65% of the total installed capacity of 1,38,175 MW in the country , as against nil in 1969 -70. As part of Indias largest Solar Power-based Island Electrification Project in India, Bharat Heavy Electricals Limited (BHEL) has successfully commissioned two Grid-Interactive Solar Power Plants of 100 KW each in Lakshadweep. With this, the company has commissioned a total of eleven Solar Power Plants in the Lakshadweep islands, adding over 1 MW of Solar Power to the power generating capacity of the coral islands in the Arabian Sea.

 BHEL has proven turnkey capabilities for executing power projects from concept to commissioning and manufactures boilers, thermal turbine generator sets and auxiliaries up to 500MW. It possesses the technology and capability to procure thermal power generation up to 1000MW. Co- generation and combined cycle plants have also been introduced. For the efficient use of high ash content coal BHEL supplies circulating fluidized boiler. BHEL manufacturers 235MW nuclear sets and has also commenced production of 500MW nuclear turbine generator sets. Custom made hydro sets of Francis, pelton and kepian types for different head discharge combination are also engineering and manufactured by BHEL. In, all 700 utility sets of thermal, hydro, gas and nuclear have been placed on thecompany as on date.The power plant equipment manufactured by BHEL is based on contemporary technology comparable to the best in the world and is also internationally competitive. The Company has proven expertise in Plant Performance Improvement through renovation modernization and up rating of variety of power plant equipment besides specialized know how of residual life assessment, health diagnostics and life extension of plants.

POWER TRANSMISSION AND DISTRIBUTION (T&D) ---

BHEL offer wide-ranging products and systems for T & D applications Products, manufactured include power transformers, instrument transformers, dry type transformers, series and shunt reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears and insulators. A strong engineering base enables the Company to undertake turnkey delivery of electric substances up to 400 kV level series compensation systems (for increasing power transfer capacity of transmission lines and improving system stability and voltage regulation), shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power). BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV Facts (Flexible AC Transmission System) project under execution.

INDUSTRY SECTOR
BHEL is a major contributor of equipment and system to important industries like Cement Petrochemicals Fertilizers Steel papers Refineries Mining and telecommunication BHEL has indigenously developed the state-of-the-art controlled shunt reactor (for reactive power management on long transmission lines). Presently a 400 kV FACTS (Flexible AC Transmission System) projects is under execution. The range of system and equipment supplied includes: Captive power plants High speed industrial drive turbines

 Industrial boilers and auxiliaries Waste heat recovery boilers Gas turbine pump, valves, seamless steel tubes Heat exchangers Process control etc. The Company is a major producer of large-size thruster devices. It also supplies digital distributed control systems for process industries, and control & instrumentation systems for power plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power plants, defence and other applications. The Company has commenced manufacture of large desalination plants to help augment the supply of drinking water to people.

TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production, installation, and maintenance and after-sales service of Rolling Stock and traction propulsion systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly applications. BHEL is also producing rolling stock for special applications viz., overhead equipment cars, Special well wagons, Railcum-road vehicle etc., Besides traction propulsion systems for in-house use, BHEL manufactures traction propulsion systems for other rolling stock producers of electric locomotives, diesel electric locomotives, electrical multiple units and metro cars. The electric and diesel traction equipment on India Railways are largely powered by electrical propulsion systems produced by BHEL. The company also undertakes retooling and overhauling of rolling stock in the area of urban transportation systems. BHEL is geared up to turnkey execution of electric trolley bus systems, light rail systems etc. BHEL is also diversifying in the area of port handing equipment and pipelines transportation systems.

TELECOMMUNICATION---

BHEL also caters to telecommunication sector by way of small, medium and large switching system.

HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP):At Hardwar, against the picturesque background of Shivalik Hills, 2 important manufacturing units of BHEL are located viz. Heavy Electrical Equipment Plant (HEEP) & Central Foundry Forge Plant (CFFP). The hum of the construction machinery working started under Shivalik Hills during early 60s and sowed the seeds of one of the greatest symbol of Indo Soviet Collaboration Heavy Electrical Equipment Plant:Consequent upon the technical collaboration between India and USSR in 1959,BHELs prestigious unit, Heavy Electrical Equipment plant (HEEP), was established in October, 1963, at Hardwar. It started manufacturing thermal sets in 1967 and now thermal sets of 210, 250 and 500 MW, including steam turbines, turbo-generators, condensers and all associated equipments, are being manufactured. This unit is capable of manufacturing thermal sets up to 1000 MW. HEEP-manufactured gas turbines, hydro turbines and generators, etc., are not only successfully generating electrical energy within and outside the country, but have also achieved a historic record of the best operational availability and plant load factor. The Company is embarking upon an ambitions growth path through clear vision, mission and committed values to sustain and augment its image as a world class enterprise.

VISION:World-class, innovative, competitive and profitable engineering enterprise providing total business solutions.

MISSION:The leading Indian engineering enterprise providing quality products systems and services in the fields of energy, transportation, infrastructure and other potential areas.

VALUES:Meeting commitments made to external and internal customers. Foster learning creativity and speed of response. Respect for dignity and potential of individuals. Loyalty and pride in the company. Team playing Zeal to excel. Integrity and fairness in all matters.

ESTABLISHMENT AND DEVELOPMENT STAGES: Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the area of Scientific, Technical and Industrial Cooperation. DRR prepared in 1963-64, construction started from October '63 Initial production of Electric started from January, 1967. Major construction / erection / commissioning completed by 197172 as per original DPR scope. Stamping Unit added later during 1968 to 1972. Annual Manufacturing capacity for Thermal sets was expanded from 1500 MW to 3500 MW under LSTG. Project during 1979-85 (Sets up to 500 MW, extensible to 1000/1300 MW unit sizes with marginal addition in facilities with the collaboration of M/s KWUSiemens, Germany. Motor manufacturing technology updated with Siemens collaboration during 1984-87.

 Facilities being modernized continually through Replacements / Reconditioning/Retrofitting, Technological / operational balancing.

CLIMATIC AND GEOGRAPHICAL CONDITIONS: Hardwar is in extreme weather zone of the Western Uttar Pradesh of India and temperature varies from 2oC in Winter (December to January) to 45oC in Summer (April-June); Relative humidity 20% during dry season to 95-96% during rainy season. Longitude 78o3' East, Latitude 29 o55'5" North. Height above Mean Sea Level = 275 meters. Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan Ranges; Ganges flows down within 7 KMs from the Factory area. HEEP is located around 7 KMs on the Western side of Hardwar city.

POWER & WATER SUPPLY SYSTEM: 40 MVA sanctioned Electric Power connection from UP Grid (132 KV / 11KV /6.6 KV) (Connected load around 185 MVA) 26 deep submersible Tube Wells with O.H. Tanks for water supply. A 12 MW captive thermal power station is located in the factory premises.

HRDC:Much before the manufacturing of the first electrical machine at HEEP, BHEL, HARDWAR, the HRD Center was established in the year 1963. Known as Technical Training School .The center was utilized for large scale fabrication activity, which helped the erection of Heavy Electrical Equipment Plant.

MANUFACTURING BLOCKS:BLOCK IELECTRICAL MACHINE BLOCK, IS DESIGNED TO MANUFACTURING OF TURBOGENERATORS. BLOCK IIFABRICATION BLOCK. BLOCK IIITURBINE BLADE BLOCK. BLOCK IVCOIL AND INSULATION MANUFACTURING & APPARATUS AND CONTROL GEAR MANUFACTURING BLOCK. BLOCK VFEEDER BLOCK AND KNOWN AS FABRICATION AND FORGE BLOCK. BLOCK VISTAMPING AND DIES MANUFACTURING BLOCK. BLOCK VIIWOODWORKING BLOCK. BLOCK VIIIHEAT EXCHANGER BLOCK, IS DESIGNED TO MANUFACTURE HEAT EXCHANGER UNIT FOR STEAM TURBINES.

TYPES OF GENERATORS:The generators may be classified based upon the cooling system used in the generators such as: THRI (200-250MW), TARI (153MW), THDI, THDD, THDF (500MW), THFF and THW. T First alphabet signifies the types of generator i.e. turbo generator or Hydro generator. H/A 2ND alphabet stands for the cooling media used for the cooling of rotor i.e. hydrogen gas or air. R/D/F/I 3rd alphabet signifies the type of cooling of rotor example radial, direct, indirect, forced, etc. I/D/F last alphabet stands for the type of cooling of stator example indirect, direct and forced. The two-pole generator uses direct water cooling for the stator winding, phase connectors and bushings and direct hydrogen cooling for the rotor winding. The losses in the remaining generator components, such as iron losses, windage losses and stray losses, are also dissipated through hydrogen. The generator frame is pressure-resistant and gas tight and equipped with one stator end shield on each side. The hydrogen coolers are arranged vertically inside the turbine end stator end shield.

BLOCK #1
Block-1 has some sections: Machine Shop Iron Assembly Balancing Tunnel Test Bed Large Size Turbo Generator(LSTG)

Block #1 has 4 bays:Bay-1 and Bay-2: In these two bays machining and assembly of the large components of generator is done.
MACHINE SECTION : This section is equipped with large size vertical boring, horizontal boring, drilling and double column planning machines. also it has milling machines, slotting machines and a shaper for machining small components for Turbo-generators. The major components machined in this section are stator frames, upper & lower brackets, rotor spider, pole & plates etc. ASSEMBLY SECTION : This section has two centering columns and sets of welding transformers for carrying out iron assembly of Turbo-generator stator.

STATOR WINDING : This section has oven for heating the bars before laying and one trunk mounted brazing installation.

Bay-3 and Bay-4:In these two bays the machining and assembly of small components of generator is done. MACHINE SECTION :

This section is equipped with large sized machine tools such as lathes, vertical boring and radial drilling machining stator body, rotor shaft, end shields, bearing etc. for turbo-generator. Also it has a special rotor slot - milling machine for cutting slots in rotor shafts. IRON ASSEMBLY : This section has facilities for stator core assembly of turbogenerators and heavy electrical motors including transformer for induction heating of retaining rings and armature cores of large size electric motors. HEAVY ROTOR ASSEMBLY SECTION : It has a 250-ton horizontal press and other necessary facilities for assembly of large size rotors. STATOR WINDING SECTION : It has 2 dust proof stands for stator winding of turbo-generators and an installation for heating stator bars.

ARMATURE / ROTOR SECTION : It is equipped with installations for laying windings in turbogenerators and large size D.C. armatures. Also it has a dynamic balancing machining for rotors up to 16- ton weight. ARMATURE / ROTOR IMPREGNATION SECTION : It has impregnation and drying ovens for large D.C. armatures.

 GENERAL ASSEMBLY SECTION : In this general section assembly of turbo-generators, large size AC and D.C. Machines are carried out.

TURBINE Boiler Electrical energy

GENERATOR Mechanical energy

CONSTRUCTIONAL FEATURES OF TURBOGENERATORS

The generator consists of following components: STATOR Stator frame Stator core Stator winding Hydrogen coolers End shields Terminal box ROTOR Rotor shaft Rotor winding Rotor wedges Rotor retaining rings Field connections Fans

 BEARINGS COOLING OF ROTOR WINDING The following additional auxiliaries are required for generator operation:-

Oil system Gas system Excitation system Cooling system Insulation system Primary water system

STATOR:STATOR FRAME:
The design of a stator frame consists of a cylindrical casting with an inner partition wall, and thick side wall and two end shields which are gas-tight and pressure-resistant. The stator end shields are joined and sealed to the stator frame. The stator frame is designed to withstand shocks and forces caused by the unlikely explosion of hydrogen. The stator frame also houses the 4 gas coolers for which an opening in all the walls of the stator are left and are aligned accurately to facilitate the insertion of the gas cooler of 210/500 MW TG. A special cradle is also provided for the purpose of transport on special well wagon, which also provides the base for jacking up while using the lifting ting. A special manhole is provided in the bottom of the frame for the purpose of access to the core and internal parts. All pipes for the supply of cooling water, hydrogen and carbon dioxide area also housed in the frame and is welded rigidly with the walls of the frame. These are made of stainless steel to avoid an induction. The stator end shields contain

the shaft seal and bearing components. Feet are welded to the stator frame and end shields to support the stator on the foundation. The stator is firmly connected to the foundation with anchor bolts through the feet.

STATOR CORE:
The stator core is assembled for alignation from electrical shell steel of high quality for 210/500 MW TG. Axial compression of the stator core is obtained by clamping fingers, pressure plates, and non-magnetic through-type clamping bolts, which are insulated from the core. The cold rolled grain oriented shell with low loss factor of 1.01 Watts/Kg. , along the direction of rolling is used.

The use of cold rolled grain oriented shell steel enables reduction in the size of the core, thus affecting an overall reduction in the size of the machine. A positive tolerance is kept so that the clear width of the slot obtained after assembly can carry stator winding bar without much difficulty. The core should be capable of expanding due

to heat all supported on 20 core bars made for fatigue resistant steel. A unique design of the core suspension is employed for 210/500MW TG using the inertia slots for the purpose of damping the core vibration to be transmitted to the stator frame.

Spring support of stator core: The flat springs are tangentially arranged on the circumference in sets with three springs each, i.e. two vertical supporting springs on both sides of the core and one horizontal stabilizing spring below the core. The springs are so arranged and tuned that forced vibrations of the core resulting from the magnetic field will not be transmitted to the frame and foundation. the complete core is subjected to heating by means of recalculated turns around the core and creating a definite value of flux in the iron. The thermocouples are located at various points on the teeth of stator core and temp. rise is measured. maximum temp. rise should not exceed 250*C.

STATOR WINDING :

Stator winding is of lap type and made from glass lapped elementary conductor and hollow conductor is sandwiched between the two solid conductors. These bars are transposed in the slot portion through an angle of 360. The slot bottom bar and top bars are displaced from each other by one winding pitch and connected at their ends to from coil groups. The coil groups are connected together with phase-connectors inside the stator frame shown in the connection diagram.

Connections:-

The stator winding employs the direct water cooled bars type of winding permits high values of current densities in the machine and thus reducing size as well as output/kg of the materials. The direction of rolling is kept perpendicular to the teeth of segment so as to get the minimum iron losses in the machine. Each of this lamination is coated with two layers of varnish that has high electrical and mechanical properties. The assembly of the core in the stator is carried out in the vertical position. The teeth portion at the each end of the stator is kept pressed by means of non-magnetic material in order to reduce losses due to stray field in the end portion and also to improve the form of field in the air gap. the losses in the end region of the stator core are reduced by means of using a copper screen between the press ring and core at the other end. INSULATION OF STATOR BAR:B.H.E.L. has planned change over to epoxy mica thermosetting insulation for stator bars to insulate the stator bar of 500 mw generators. The mica tape consists of a thin high-strength backing material to which the mica is bounded by synthetic resin. The number of layers, i.e, the thickness of insulation, is determined by the voltage of the machine. The

taped bars are then dried under vacuum and impregnated with epoxy resin which, by reason of its low viscosity penetrates the insulation thoroughly and eliminates all voids. After impregnation under vacuum, the bars are subjected to pressure, with nitrogen being used as pressurizing medium (VPI process). CORONA PROTECTION:After the final compounding the stator winding bar is coated with anti corona coating paint which provides a gradual potential gradient across the thickness of the insulation. This protection consists of a wear resistant, highly flexible coating of conductive alkyd varnish containing graphite. In the case of manufacture of the stator winding bar special attention is paid to the quality of materials

1- Stator bar (slot end) 2- High-voltage insulation 3-Outer corona protection 4-Transition coating 5-End corona protection 6-Glass tape-epoxy protective layer 7-Stator bar (end winding) TESTS ON HOLLOW CONDUCTOR :-

 Checking for cracks, splits and overlapping Checking for the dimension for duct Hydraulic test at 70 atm. COMPLETE WINDING BAR : Inter turn insulation test Hydraulic test of the complete bar Flow measurement Pneumatic test of the bar High voltage test of bar Tan delta measurements

Electrical connection of bars:The electrical connection between the top and bottom bars is by a bolted contact surface. At their ends the strands are brazed into a connecting sleeve, the strand rows being separated from each other by spaces. The contact surfaces of the connecting sleeves for the top and bottom bars are pressed against each other by non-magnetic clamping bolts. Special care is taken to obtain flat and parallel contact surfaces.

HYDROGEN COOLERS:
The hydrogen cooler is a shell and tube type heat exchanger which cools the hydrogen gas in the generator. The heat removed from the hydrogen is dissipated through the cooling water. The cooling water flows through the tubes, while the hydrogen is passed around the finned tubes. The hydrogen cooler is subdivided into identical sections which are vertically mounted in the turbine-end stator end shield. The cooler sections are solidly bolted to the upper half stator end shield, while the attachment at the lower water channel permits them to move freely to allow for expansion. The cooler sections are parallel-connected on their water sides. Shut-off valves are installed in the lines before and after the

cooler sections. The required cooling water flow depends on the generator output and it is adjusted by control valves on the hot water side. Controlling the cooling water flow on the outlet side ensures an uninterrupted water flow through the cooler sections so that proper cooler performance will not-be impaired.

END SHIELDS:
The ends of the stator frame are closed by pressure containing end shields. The end shields feature a high stiffness and accommodate the generator bearings, shaft seals and hydrogen coolers. The end shields are horizontally split to allow for assembly. The end shields contain the generator bearings. This results in a minimum distance between bearings and permits the overall axial length of the TE end shields to be utilized for accommodation of the hydrogen cooler sections. Cooler wells are provided in the end shield on both sides of the bearing compartment for this purpose. One manhole in both the upper and lower half end shield provided. Inside the bearing compartment the bearing saddle is mounted and insulated from the lower half end shield. The bearing saddle supports the spherical bearing sleeve and insulates it from ground to prevent flow of shaft currents. The bearing oil is supplied to the bearing via a pipe permanently installed in the end shield and is then passed on to the lubricating gap via ducts in the lower bearing sleeve. The bearing drain oil is collected in the bearing compartment and discharged from the lower half of the end shields via a pipe.

TERMINAL BOX:
The phase and neutral leads of the three-phase stator windings are brought out of the generator through six bushings located in the generator terminal box at the exciter end of the generator. The terminal box is a welded construction of nonmagnetic steel plate. This material reduces stray losses due to eddy currents. Welded ribs are provided for the rigidity of the terminal box. Six manholes in the terminal box provide access to the bushings during assembly and overhauling.

ROTOR:-

Rotor shaft:

The cylindrical rotor with non-salient pole forms one of the most important part of the turbo-generator, which is loaded to the maximum limit of mechanical strength of the material as well as heat transfer capability. Due to the high speed of rotation high mechanical centrifugal stresses are encountered in the rotor teeth as well as in the rotor retaining ring. These mechanical forces are varying in nature and due to unequal moment of inertia across the two axis cause the vibration in the machine. The rotor is machined from a solid alloy steel single piece forging with high mechanical properties.

The rotor forging is heat-treated and stress relieved at the forging plants. The rotor forging, before is dispatched to the manufacturing plant is heat stabilized at 400 to 500 degree Centigrade on a special furnace where the rotor rotates at a slow speed of 2 to 4 rpm. The rotor is machined on the lathes followed by the machining of the rotor slots on the special milling

machine. The depth of the rotor slot is governed by the thickness of the teeth. The rotor winding in turbo-generator is manufactured from The silver in small percentage of 0.6 to 1% added to increase softening temperature encountered in operating life of the machine. The winding is formed in the form of half coils, which are insulated by means of glass textolite formed along with each turn of coils.

ROTOR WINDING

The rotor winding is installed in the slots machined in the forging main body and is distributed symmetrically around the rotor between the poles. The winding itself is made up of many turns of copper to form the entire series connected winding. All of the turns associated with a single slot are called a coil. The coils are wound into the winding slots in the forging, concentrically in corresponding positions on opposite sides of a pole. The series connection essentially creates a single multi-turn coil overall, that

develops the total ampere-turns of the rotor (which is the total current flowing in the rotor winding times the total number of turns). Insulation:The insulation between the individual turns is made of layers of glass fiber laminate. The coils are insulated from the rotor body with L-shaped strips of glass fiber laminate with Nomex filler. To obtain the required creepage paths between the coil and the frame, thick top strips of glass fiber laminate are inserted below the slot wedges.

ROTOR WEDGES :

The protection against the effect of centrifugal force the winding is secured in the slots by slot wedges. The wedges are made from Duralumin, an alloy of Copper, Magnesium, and Aluminum having high good electrical conductivity and high mechanical strength. The slot wedges behave as damper winding bars also under unbalanced operation of generator. The wedges at the ends of slot are made from an alloy of chromium and copper having high electrical conductivity. These wedges are connected with damper segments under the retaining ring for short circuiting induced shaft current. The end wedges are insulated from retaining rings by glass textolite liner.

RETAINING RING :

The overhang portion of the field winding is held by nonmagnetic steel forging of retaining against centrifugal forces. They are shrink fitted to the ends of the rotor body barrel at one end, while the other side of retaining ring does not make contact with the shaft thus

ensuring an unobstructed shaft deflection at the end winding and eliminating the chances of corrosion.

FIELD CONNECTIONS:

The field connection provides the electrical, connection between the rotor winding and the exciter and consists of: ield current lead at end winding F Radial bolts Field current lead in shaft bore

Field current lead at end winding:The field current lead at the end winding consists of hollow rectangular conductors. The hollow conductors are inserted into shaft slots and insulated. Those are secured against the effects of centrifugal force by steel wedges. One end of each field current lead is brazed to the rotor winding and the other end is screwed to a radial bolt. Cooling hydrogen is admitted into the hollow conductors via radial bolts. The hot gas is discharged into the air gap together with the gas used to cool the end winding.

Radial bolt:The field current leads located in the shaft bore are connected to the conductors inserted in the shaft slots through radial bolts which are secured in position with slot wedges. Contact pressure is maintained with a tension bolt and an expanding cone in each radial bolt. Contact pressures increase due to centrifugal force during operation. All contact surfaces are silver-plated to attain a low contact resistance. The radial bolt is made from forged electrolytic copper.

Field current lead in shaft bore:-

The leads are run in the axial direction from the radial bolt to the exciter coupling. These consist of two semicircular conductors insulated from each other and from the shaft by a tube. The field current leads are connected to the exciter leads at the coupling with multi contact plug-in contact which allow for unobstructed thermal expansion of the field current lead.

FANS :

The generator cooling gas is circulated by two single stage axial flow propeller type fans. The fans are shrink fitted on either side of rotor body. Fan hubs are made of alloy steel. Fan blades which are precision castings with special alloy are machined in the tall portion. To check the fan blades from coming out of the hub, ground tapered pins are used by reaming the two components together.

BEARINGS :

Depending upon the size and application of the machine, the bearing selection is done.

ROLLING BEARINGS:The rolling bearings are self-aligning and suitable for a long life of minimum 60,000 hours up to approximate 100,000 hours. The bearings require practically no servicing and are lubricated by the oil which is stored in the sump of bearing assembly. They are able to withstand high axial pressure because there is no critical speed range. The main rotor body must be supported by a bearing at each end of the generator.

SLEEVE BEARINGS:-

The rotor shaft is supported in sleeve bearings having forcedoil lubrication. The lower bearing sleeve rests on the bearing saddle via three brackets with spherical support seat for self-alignment of the bearing. The bearing saddle is insulated from the stator end shield and the bearing brackets are insulated from the bearing sleeve to prevent the flow of shaft currents and to provide for double insulation of the generator bearing from ground. All generator bearings are provided with a hydraulic shaft lift oil system to reduce bearing friction during startup. High pressure oil is forced between the bearing surface and the shaft journal, lifting the rotor shaft to allow the formation of a lubricating oil film.

VENTILATION AND COOLING SYSTEM:VENTILATION SYSTEM:The machine is designed with ventilation system having rated pressure. The axial fans mounted on either side of rotor ensure circulation of hydrogen gas. The rotor is designed for radial ventilation by stem. The end stator is packets and core clamping and is intensively cooled through special ventilation system. Design of special ventilation system. Design of special ventilation is to ensure almost uniform temperature of rotor windings and stator core.

COOLING SYSTEM:STATOR COOLING SYSTEM:-

The stator winding is cooled by distillate water which is fed from one end of the machine by Teflon tube and flows through the lower bar of slot. Turbo generator requires water cooling arrangement over and above the usual hydrogen cooling arrangement. The stator is cooled in this system by circulating demineralized water through hollow conductors. The cooling was used for cooling of stator winding and for the use of very high quality of cooling water for this purpose DM water of proper specifying resistance is selected. Generator is to be loaded within a very short period. If the specific resistance of cooling DM water goes beyond preset value. The system is designed to maintain a constan rate of cooling water flow through the stator winding at a nominal inlet with temperature of 40 degree centigrade, the cooling water is again cooled by water is also demineralized to avoid contamination with any impure water in case of cooler tube leakage, the secondary DM cooling water is in turn cooled by clarified water header.

ROTOR COOLING SYSTEM:The rotor winding are cooled by means of direct cooling method or gap pick up method. In this type of cooling the hydrogen in the gap is sucked through the elliptical holes serving as scoop on the rotor wedges and is directed to flow a long lateral vent ducts on rotor copper coil to bottom of the coil.

The overhang portion of the winding is cooled by axial two flow system and sectionalized into small parallel paths to minimize the temperature rise. Cold gas enters the overhang from under the retaining rings through special chamber in the end-shields and ducts under the fan hub and gets released into the air gap at the rotor barrel ends.

HYDROGEN COOLING SYSTEM:Hydrogen is used as a cooling medium in large capacity generator in views of highest carrying capacity and low density. Also in order to prevent hydrogen from generators, casing and sealing system is used to provide oil sealing. The system is capable of performing following system: Filing in and purging of hydrogen safely without bringing in contact with air. Maintaining the gas pressure inside the machine at desired value at all times.

Providing indication to the operator about the condition gas inside the machine i.e. the pressure, temperature and purity. Continuous circulation of gas inside the machine through a drier in order to remove any water vapors that may be present in it. Indication of liquid level in the generator and alarm in case of high level.

OTHER SPECIFICATIONS OF STATOR AND ROTOR:

(i)Stator Insulation :- It is done with thermosetting epoxy mica tape,
on slot portions as well as on overhang. (ii)Corona Prevention :- To prevent corona b/w insulation and slotwall, semi-conducting varnish is applied b/w them. (iii)Copper conductor:- Made up of hard drawn silver bearing copper, having high creep resistance, to avoid deformation. (iv)Rotor Insulation :- Individual turns are insulated from each other by glass laminates. Also to increase creeping distance b/w the coils and rotor body very thick top packing are placed. (v)Cooling System :- The heat losses arising in the generator interior are dissipated through hydrogen and secondary coolant. Direct cooling of the rotor essentially eliminates hot spots and differential temp. between adjacent components, which may deform rotor body and insulation.

BRUSHLESS EXCITATION TURBOGENERATORS:-

SYSTEM

FOR

An important characteristic of large turbo-generator is that the excitation requirements increased sharply with the rating of the m/c. since excitation voltage is limited from insulation considerations, excitation current levels increase sharply.

Brush-less excitation system connected through driven revolving armature a.c. exciter connected through shaft mounted rectifiers to the rotating field of the turbo generator with no coupling of excitation power between the source of generation and point of supply to the generator field. Today, leading manufacturers offer brush-less excitation with rotating diodes as the preferred excitation system.

CONTRUCTIONAL FEATURES OF BRUSHLESS EXCITER :The three phase pilot exciter is of revolving field type with permanent magnet poles. The three-phase a.c. generated in the stator is fed to the field of revolving armature main exciter via a stationary regulator and rectifier unit. The three-phase a.c. induced in the rotor of the main exciter is rectified in the rotating Rectifier Bridge, (i.e. diode wheels) and fed into the field winding of the generator rotor through the a.c. lead in the rotor shaft. A common shaft carries the rectifier wheels, the rotor of the main exciter and the permanent magnet rotor of the pilot exciter, arranged one behind the other. The shaft is rigidly coupled to the generator rotor at its driving end and supported on a journal bearing at its non-driving end. The generator and exciter rotors are thus supported in a total of 3 bearings.

BLOCK DIAGRAM OF BRUSHLESS EXCITER:-

 BALANCING TUNNEL:
The 500mw Turbo-generator is keeps on this balancing tunnel ands rotates it on above of its rated rpm. Rotors are sensitive to residual unbalance that is a major source of vibration. All the rotors are dynamically balanced at rated speed along with the fans. This ensures smooth running of motor, while in operation.

TEST BAD:

Different types of testing of generators are done in the test bed like open circuit test, short circuit test, sudden short circuit test, no load test, full load test, heat run test etc.

HELIUM LEAK TEST PURPOSE

To check any leakage of gas from stator and rotor as if there is any leakage of gas used for cooling such as hydrogen then it may cause an explosion. Testing of stator frame involves two types of testing: HYDRAULIC TESTING AND PNEUMATIC TESTING:Hydraulic testing involves in empty stator frame with attached end shields and terminal box is subjected to a hydraulic test at 10 bar to ensure that it will be capable of withstanding maximum explosion pressure.

The pneumatic testing involves filling of hydrogen in the sealed stator frame and then soap water is used to check the leakage of welding.

TECHNICAL TESTING DATA :RATING VOLTAGE CURRENT P.F. FREQUENCY NO LOAD EXCITATION CURRENT S.C. EXCITATION CURRENT FULL LOAD EXCITATION CURRENT FULL LOAD EXCITATION VOLTAGE MECHANICAL LOSSES IRON LOSSES EXCITER CONST. LOSSES EXCITER VAR. LOSSES ROTOR CU LOSSES S.C. LOSSES+STRAY LOAD LOSSES TOTAL LOSSES EFFICIENCY 500MW 21 KV 16.166KA 0.85 LAGGING 50 HTZ 1378 A 2655 A 4040 A 340 V 1850KW 598KW 380KW 47KW 1320KW 2693KW 6888% 98.64%

BLOCK # II
This block is known as the Fabrication Block or a feeder Block for various products - steam turbines, hydro turbines and turbo generators, Hydro-generators, electrical machines and apparatus and control gears. The Block consists of four bays. This Block has facilities for compressed air, oxygen, acetylene and carbon dioxide gas pipelines. Different types of coolers are also fabricates in this block like

exciter air cooler, hydrogen cooler etc. Exciter Air Cooler cools the air inside the generator which is then passes through these coolers. Hydrogen Coolers are used to cool the hydrogen gas which is flowing inside the turbo-generator.

BLOCK # III
This is the major block for manufacturing turbines known as Turbine Block. All types and different stages of Hydro, Steam, Gas and Nuclear Turbines and turbine blades are manufactured and dispatched from this block.

BLOCK # IV
This Block is Known as the Apparatus and Control Gear and coil and Insulation Manufacture Block. Block-IV is feeder block for insulating items, windings and sheet-metal components for all the products of Block-I i.e. Turbo-generator, Hydro-generator, A.C. and D.C. motors. Block-IV consist 3 bays:BAY-1(BAR WINDING SHOP): Manufacturing of stator winding bars of generators. BAY-2: Manufacturing of motor stator coil, d.c. armature coil, main pole coil interpole coil, equalizer coil etc. Manufacturing of heavy duty generator stator bars with new CNC machine. BAY-3(INSULATION DETAIL SHOP): Manufacturing of Hard Insulation & machining of hard insulation part(Glass Texolite) such as packing, washer, insulation box, wedges. BAR SHOP:

This shop means Manufacturing of stator winding & coils of generator that may be Turbo-generator or Hydro-generator. Why do we call it BARS?? It is quite difficult to manufacture, handle and wind the coil in stator slot of generator of higher generation capacity because of its bigger size and heavy weight. That is why we make coil in two parts-one part is bottom part of coil called bottom or lower bar and other part of coil is called top bar or upper bar. HYDRO GENERATOR BARS(HG BARS):The manufacturing of bars of different capacity as required by the customer depends upon the water head available at site. The Hydro generator is air cooled generator of lesser length in comparison to its bigger diameter.

TURBOGENERATORS(BARS):The manufacturing of bars of standard capacity such as: 100MW, 130MW, 150MW, 210/235MW, 210/250MW, 500MW . The plant has capacity and technology to manufacture 800MW and 1000MW generators.

BLOCK#5
BLOCK-V is known as the FABRICATION AND FORGE BLOCK. It consists of two bays. Fabrication work is carried out in bay-I and forgings are made in bay-II.

 FABRICATION SECTION : Fabrication work being done in this bay is of steam turbine parts like condenser upper part (left & right), water box (front & rear), middle part of LPC, storage tanks etc. and Hydro turbine parts like outlet pipes, inlet pipes, cylindrical parts etc. Fabrication of Hydro generator pipe, conical rotor spider and grinding of hydro turbine fluid vanes and stray vanes is also carried out. FORGE SECTION : Forging of carbon alloy and stainless steel are manufactured in this section. This is equipped with pneumatic hammers from 100 kg to 3 tons capacity. Gas fixed furnaces for heating of blooms and for subsequent heat treatment of forging, hydraulic manipulator of 2 ton capacity is used to handle the forging on 3 tons hammer. The blooms re-heating furnaces available in this section can accommodate a job of 1500mm length and can be heated to a max. temperature of 1300*C.

BLOCK#6
Block-VI is known as the STAMPINGS AND DIES MANUFACTURE BLOCK. Block-VI has 3 bays: Bay-I is for manufacturing all types of dies Bay-II is for manufacturing stampings for Turbo-generators and motors. Bay-III is also known as Engineering Works Section.

STAMPING MANUFACTURE :
Press Section :

It is equipped with presses varying from 10 T to 500 T. Shearing machines, segmental and radial notching machines. Shearing, blanking and punching operations are carried out here to form stampings of various products. De-burring, Degreasing and De-rusting : A contractor carries this out before feeding them to varnishing section. Varnishing Section, Spot Welding and Painting Section : This section is equipped with 2 varnishing machines, 2 spot welding machines and 1 paint-spraying booth. Here varnishing, coating, spacers cutting, spot welding and painting operations are carried out.

STAMPING:-

This Section is divided into 3 Zones according to temperature:I Zone - 25020 degree II Zone - 35020 degree

III Zone -

45020 degree

BLOCK#7
This Block is known as the Wood Working Block. Block-VII has got 2 bays: Bay-I known as the pattern section is equipped with various wood working machine tools like groove cutting machines, wood working lathes, surface planer, pendulum saw etc. This section is making patterns for CFFP as per their requirement of various castings. Bay-II known as the packing section, package for packing and dispatch of various products are manufactured here.

BLOCK#8
This Block is known as the Thermal Power Block. Block-VIII is adjacent to the center plant stores building and got 1 bay only. Heat exchange units like LP Heaters, HP Heaters, Coolers, Ejectors, Heat Exchanger of Steam turbines, Hydro turbines are manufactured here.

CDS 1 OF HEEP:->

This is central distribution system of electric in heavy electrical equipment plant.

CFFP(CENTRAL FOUNDRY AND FORGING PLANT) #

In this section of plant main forging and foundry and moulding process are done. There is a large size machine shop to finish the job surface coming from foundry and forge shop. In the electrical point of view there is a furnace known as steel melting furnace. This furnace takes largest load of the plant as about 15000 to 20000amp.

There are three furnaces of diff. capacities as 40mva, 12mva, 5mva. The 40mva furnace of capacity 70 tons is run at night only as it takes too much current and so at night whole plant gets shut down. In these furnaces three graphite electrodes placed at same distance from each other. The supply of 33kv three phase AC is given to these electrodes so a large arc produce at the lower point so due to this arc a temperature about 1600degree Centigrade is produce. And the steel melts at this high temperature and dispatched to the moulding section.

Machine hall #
In this section the power supply for large motor is prepared at variable voltage and variable frequency which rotates the rotor of LSTG at 3000 rpm for testing on test bed.

CONCLUSION:
The Vocational training at Bhel Haridwar helped me in improving my practical knowledge and awareness regarding Turbo Generator to a large extent. Here I came to know about the technology and material used in manufacturing of turbo generators. Besides this, I also visualized the parts involved or equipment used in the power generation. Here I learnt about how the electrical equipment are being manufactured and how they tackle the various problems under different circumstances. At least I could say that the training at BHEL Haridwar is great experience for me and it really helped me in making or developing my knowledge about turbo generator and other equipment used in power generation.

REFRENCES:
Material provided by training in charge. Internet