BHEL - AN OVER VIEW

BHEL is the largest engineering and manufacturing enterprise in India in the energy related in fracture sector to day. BHEL was established more than 40 years ago when its first plant was set up in Bhopal ushering in the indigenous Heavy Electrical Equipment industry in India a dream that has been more than reali!ed with a well"recogni!ed tract record of performance. It has been earning profits continuously since #$%#"%& and achieved a sales turnover of 's. %4(&.) crores with a profit before ta* of 's. (0&.4 crores in &00& + &00). BHEL caters to core sectors of the Indian Economy ,i!. -ower .eneration / 0ransmission Industry 0ransportation 0elecommunication 'enewable Energy 1efence etc. 0he wide networ2 of BHEL34 #4 manufacturing divisions four -ower 4ector regional centers eight service centers and #( regional offices and a large number of pro5ect sites spread all over India and abroad enables the company to promptly serve its customers and provide them with suitable products systems and services efficiently and at competitive prices. BHEL has already attained I46 $000 and all the ma5or units7divisions of BHEL have been upgraded to the latest I46" $00#8 &000 version quality standard version quality standard certification for quality management. BHEL has secured I46 #400# certification for environmental management systems and 6H494 + #(00# certification for occupational health and safely management systems for its ma5or units7 divisions.

Power Generation8
-ower .eneration 4ector comprises of thermal gas hydro and nuclear power plant business. 9s of )#.).&00) BHEL supplied sets account for nearly :( (;4 <= or :;> of the total installed capacity of # 0: &#: <= in the country as against ?il till #$:$"%0. BHEL has proven turn2ey capabilities for e*ecuting power pro5ects from concept to commissioning. It processes the technology and capability to produce thermal sets with super critical parameters up to #000 <= unit rating and gas turbine generator sets of up &;0 <= units rating. @o" generation and combined cycle plants have been introduced to achieve higher plant efficienciest. 0o ma2e efficient use of the high ash content coal available in India BHEL also supplies circulating fluidi!ed bed combustion boilers for thermal plants. 0he company manufactures &&07&);7;00 <= nuclear turbine generator sets. @ustom made hydro sets of Arancis -elton and Baplan types for different head discharge combinations are also engineered and manufactured by BHEL. In all orders for appro*imately (00 utility sets of thermal hydro gas and nuclear have were placed on the company as on date. 0he power plant equipment manufactured by BHEL is based on contemporary technology comparable with the best in the world and is also internationally competitive.

0he

@ompany

has

proven

e*pertise

in

-lant

-erformance

Improvement through renovation moderni!ation and up rating of a variety of power plant equipment besides speciali!ed 2now how of residual life assessment health diagnostics and life e*tension of plants.

TRANSMISSION & DISTRIBUTION (T&D):

BHEL offers wise ranging products and systems for 0/1 applications. -roducts manufactured include8 -ower transformers instrument transformers dry type transformers series / shunt reactors capacitor ban2s vacuum / 4A: circuit brea2ers gas insulated switchgears energy meters 4@919 systems and insulators. 9 strong engineering base enables the company to underta2e turn2ey delivery of substations up to 400 B, level series compensation systems CAor increasing power transfer capability of transmission lines and improving system stability and voltage regulationD shunt compensation systems and H,1@ systems Cfor economic transfer of bul2 powerD. BHEL has indigenously developed the state of the art controlled shunt reactor Cfor reactive power management on long transmission linesD -resently # 400 2, A9@04 CAle*ible 9@ 0ransmission systemD pro5ect is under e*ecution. 0he company underta2es comprehensive pro5ects to reduce 90 @loses in distribution 4ystems.

INDUSTRIES:
BHEL is a ma5or contribution of equipment and systems to industries8 cement sugar fertili!er refineries petrochemicals paper oil and gas metallurgical and other process industries. 0he range of systems / equipment supplied includes8 captive power plants co"generation plants 1. power plants industrial steam turbines industrial boilers and au*iliaries waste heat recovery boilers gas turbine heat e*changers and pressure vessels centrifugal compressors electrical machine pumps valves seamless steel tubes electrostatic precipitators fabric filters reactors fluidi!ed bed combustion boilers process controls and material handling systems. 0he company is a ma5or producer of large + si!e thruster devices. It also supplies digital distributed control systems for process industries and control / instrumentation systems for power plant and industrial application. BHEL is the only company in I?1I9 with the capability to ma2e simulators for power plants defense and other applications. 0he company has commenced manufacture of large desalination plants to help augment the supply of drin2ing water to people.

RENEWABLE ENERGY:
0echnologies that can be offered by BHEL for e*ploiting non"conventional and renewable sources of energy include8 wind electric generators solar photovoltaic systems stand"alone / grid + interactive solar power plants solar heating systems solar lanterns and battery"powered road vehicles. 0he @ompany has ta2en up '/1 efforts for development of multi"5unction amorphous silicon solar cells and fuel based systems.

OIL & GAS:

BHEL is a ma5or contribution to the 6il and .as sector industry in the country. BHEL Es product range includes 1eep 1rilling 6il 'igs <obile 'igs =or2 6ver 'igs =ell Heads and F"<as 0rees @ho2e and Bill <anifolds Aull Bore .ate valves <ud valves <ud"line suspension system @asing support system sub sea well Heads bloc2 valves seamless pipes <otors compressors Heat E*changers etc. BHEL is the single largest supplier of well Heads F" mass 0rees and 6il 'ings to 6?.@ and 6IL.

Environ enta! Po!i"#:

@ompliance with applicable Environmental Legislation7'egulation. @ontinual Improvement in Environment <anagement 4ystems to protect our natural environment and @ontrol pollution. -romotion of activities for conservation of resources by Environmental <anagement. Enhancement of Environmental 9wareness amongst employees customers and suppliers. BHEL will also assist and co"operate with the concerned .overnment 9gencies and 'egulatory Bodies engaged in environmental activities offering the @ompany3s capabilities in this field.

O""$%ationa! &ea!t' an( Sa)et# Po!i"#*

@ompliance with applicable Legislation and 'egulations. 4etting ob5ectives and targets to eliminate7control 7 minimi!e ris2s due to 6ccupational and 4afety Ha!ards.

9ppropriate structured training of employees on 6ccupational Health and 4afety COH

& S) aspects.

Aormulation and maintenance of 6H / 4 <anagement programs for continual improvement. -eriodic review of 6H/4 policy to all employees and interested parties. 0he ma5or units of BHEL have already earned international recognition by implementation of I46 #400# Environmental <anagement 4ystem and 6H494 #(00# 6ccupational Health / 4afety <anagement system. In pursuit of these -olicy requirements BHEL will continuously strive to improve wor2 practices in the light of advances made in technology and new understandings in 6ccupational Health 4afety and Environmental 4cience.

SYNOPSIS:+
<a*imum percentage of total power generation is obtained by conventional power plant. 6f used. In such alternators insulation plays a vital role of these insulation types resin poor thermosetting types of C,-ID of insulation is preferred as its life period is above ;00 years / as its posses good mechanical thermal properties / dielectric strength as the quantity of resin Cthe insulating material D used here is less so the overall cost of insulation is reduced . these steam diesel / gas turbine power plant are high speed systems / here always three phase alternator are only

In our pro5ect we have a detail study of the ,-I system of insulation of TURBO GENERATOR / its performance is assessed.

I?0'61G@0I6? -ower is the basic necessity for the economic development of a country. 0he production of electrical energy and its per+capital consumption is deemed as an inde* of the standard of living in a nation in the present day civili!ation. 1evelopment of heavy or large scale industries as well as medium scale industries agriculture transportation etc. totally depend on electric power resources of engineers and scientists to find out ways and means to supply required power at cheapest rate. 0he percaptia consumption on average in the world is around #&00B=H. 0he figure is very low for our country and we have to still go head in power generation to provide a descent standard of living for people. 0he need for immediate increase in the country3s power production in vital. 4o we have to utili!e the available resources in better possible manner. 9n 9@ generator is basically a device for converting mechanical energy to electrical energy. 0he alternator ma2es use of the e*periment fact that if a conductor is moved through a magnetic field an e.m.f is induced in it. 0he magnitude field of this induced e.m.f depends upon the length of conductor actually in the field the speed of the relative motion between the conductor and the magnetic field and the strength of the field. 0he direction of polarity of the induced e.m.f is such that the resulting current flow and the magnetic field around the conductor produced by it tend to oppose the motion which is producing the e.m.f. In 9@ generator the stator holds the armature winding and rotor bloc2s up the field winding. In generator the armature is stationary the field is rotating. Aor the rotating magnetic field the 1@ e*citation is necessary.

1@ supply to the rotor winding of a 0urbo generator is required for voltage generation .0his is 2nown as e*citation. 9s the name suggests when the generator gets e*cited it produces the voltage. 0he e*citation is supplied using a 1@ machine called e*citer. E*citer is generally driven with the same shaft.

ELECTRICAL MACHINES
<achine acts as a generator converts the mechanical energy into electrical energy. 0he machine which acts as a motor converts electrical energy into mechanical energy 0he basic principle of rotating machine remains the same i.e.
FARADAYS LAWS OF ELECTRO MAGNETIC INDUCTION !

Aaraday3s first law states that whenever conductor cuts magnetic flu* dynamically induced E<A is produced. 0his E<A causes a current flow if the circuit is closed. Aaraday3s second law states that E<A induced in it is proportional to rate of change of flu*. e H "? d7dt E<A induced will oppose both the flu* and the rate of change of flu*. In the case of 9@ generators the armature winding is acts as stator and the field winding acts as rotor. Efficiency of a machine is equal to the ratio of output to input H 6utput 7 input H 6utput 7 Coutput I lossesD

0o increase the efficiency of any machine we must decrease the losses but losses are inevitable. 0here are different types of losses that occur in a generator.

0hey are broadly divided into & types C#D Constant losses CaD CbD C&D CaD Iron losses Ariction and windage losses Cair friction lossesD. @opper losses

Variable losses

Electrical machines are of two types 9@ machines / 1@ machines. 9@ machines are divided into single"phase 9@ machines and polyphase 9@ machines
) -hase 9@ machines are divided into

SYN,&RONOUS MA,&INES8 4ynchronous .enerators CorD 9lternators are those in which the speed of the rotor and flu* are in synchronism & ASYNCHRONOUS MACHINES8 0hese are the machines in which the flu* speed and rotor speed will not be the same.

E*8 Induction motors. Inherently all the machines are 9@ machines. 9@ or 1@ depends upon the flow of current in the e*ternal circuit.

4ynchronous generators can be classified into various types based on the medium used for generation. #. 0urbo"9lternators 4team CorD .as &. Hydro generators ). Engine driven generators In every machine they are two parts C#D Alu* carrying parts C&D Load carrying parts In large synchronous machines the stator have the load carrying parts i.e. armature and the rotor has the flu* carrying parts i.e.J field winding. Iron losses are also called as magnetic losses and core losses. 0hey are broadly divided into C#D Hystersis losses C&D Eddy current losses 0hese losses occur in the stator core. @opper losses occur in both stator and rotor winding. 0he general efficiency of a synchronous generator is $;"$(% 0he main parts in a synchronous"generator are STATOR, ROTOR, EXCITATION SYSTEM, COOLING SYSTEM, INSULATION SYSTEM, BEARINGS STATOR: ! 1. Stator frame 2. Stator core 3. Stator windings 4. Stator end covers

5. Output leads / bushings RO OR! " 1. Rotor body 2. Rotor winding 3. Rotor shaft 4. Rotor retaining rings 5. #ans $. #ield connection I! "

STATOR"
40906' A'9<E8 0he stator frame is hori!ontally split type and welded

construction and supports the lamination core and the winding. Both the air duct pieces and welded radial ribs provide for rigidly to the stator frame. 0wo things are provided to the stator frame to support the stator on the foundation. 0he stator firmly fi*ed to the foundation plates with bolt through the feet. &. 40906' @6'E8 0he stator core is made up of stac2ed insulation electrical sheet steel lamination with a low loss inde* and suspended in the stator frame from insulated rectangular guide bars. 9*ial compression of the stator core is obtained by clamping fingers pressure plates and non magnetic clamping bolts which are regulated from the core. 0he clamping finger ensures a uniform clamping pressure especially within the range of the teeth and provided for uniform intensive cooling of stator core ends.

). 40906' =I?1I?.8 0he stator winding is a fractional pitch two layer type it consisting of individual bars. 0he bars are located in slots of rectangular cross section which are uniformly distributed on the circumference of the stator core. In order to minimi!e losses the bars are compared of separately insulated strands which are e*posed to ):0degrees transposing 0o minimi!e the stator losses in the winding the strands of the top and bottom bars are separately bra!ed and insulated from each other.

II ROTOR"
" ROTOR SHA#T: 'otor shaft is a single piece solid forging manufactured from a vacuum casting. 4lots for insertion of field winding are milled into the rotor body. 0he longitudinal slots are distributed over the circumference. 4o that solids poles are obtained. 0o ensure that only high quality forgings are used strengthen test material analysis and ultrasonic tests are performed during manufacture of the rotor. 9fter completion the rotor is based in various planes at different speeds and then sub5ected to an over speed test at #&0> of rated speed for two minutes. $ ROTOR %IN&ING AN& RETAINING RINGS: 0he rotor winding consisting of several coils which are inserted into the slots and series connected such that two coils groups from one pole. Each coil consists of several connected turns each of which consists of two half turns which are connected by bra!ing in the end section.

0he individual turns of the coils are insulated against each other the layer insulation L"shaped strips of lamination epo*y glass fiber with noma* filler are used for slot insulation. 0he slot wedges are made of high electrical conductivity material and thus act as damper winding. 9t their ends the slots wedges are short circuited through the rotor body. 0he centrifugal forces of the rotor end winding are contained by single piece of non magnetic high strengthen steel in order to reduce stray losses each retaining rings with its shrin2s fitted insert ring is shrun2 into the rotor body in an overhang position. 0he retaining rings are secured in the a*ial position by a snap ring.

-* #IEL& CONNECTION AN& MULTICONTACTS:

0he field current is supplied to the rotor through multi contact system arranged at the e*citer side shaft end. III BEARINGS: 0he generator rotor is supported in two sleeve bearings. 0o eliminate shaft current the e*citer and bearing is insulated from foundation plate and oil piping. 0he temperature of each bearing is maintained with two '013s C'esistance 0emperature 1etectorD embedded in the lower bearing sleeve so that the ensuring point is located directly below the Babbitt. 9ll bearings have provisions for fitting vibration pic2 up to monitor shaft vibrations. 0he oil supply of bearings is obtained from the turbine oil system.

EXCITATION SYSTEM:
In all industrial applications the electrical power demand is ever increasing. 0his automatically demands for the design development and construction of increasingly large capacity 4ynchronous generators. 0hese generators should be highly reliable in operation to meet the demand. 0his calls for a reliable and sophisticated mode of e*citation system. =hen the first a.c generators were introducing a natural choice for the supply of field systems was the 1@ e*citer. 1@ e*citer has the capability for equal voltage output of either polarity which helps in improving the generator transient performance. 1@ e*citers how ever could not be adopted for large rateings because of the problems in the design commutator and brush gear which is economically unattractive. 6f +course the problems are not uncommon in power stations but 6f the environment with sulphur vapours acidic fumes as in the cases of petrochemical and fertili!er industries e*posure of 1@ e*citer. 0his adds to the problem of design. 0ypes of a.c e*citers are8 C#D High frequency e*citation C&D Brush less e*citation C)D 4tatic e*citation 0he high frequency 1.@ e*citer is a specially designed Kinductor type alternatorL with no winding on its rotor. It is designed to operate at high frequency to reduce the si!e of the rotorJ the a.c e*citer was very reliable in

operation. 0hough this system eliminates all problems associated with commutator it is not free from problems attributable to sliprings and its brush gear. 0hus brushless e*citation system was introduced. 0he BL e*citer consists of field winding on the stator. 0his system proved to be highly reliable and required less maintenance. 9bsence of power cables and e*ternal ac power supplies males the system e*tremely reliable. 0he problem associated with brushes li2e fast wear out of brush spar2ling etc are eliminated. 0his suffers from the disadvantage of lac2 of facility for field suppression in the case of an internal fault in generator. 0he system comprises shaft driven 9@ e*citer with rotating diodes. 'ERMANENT MAGNET GENERATOR AN& AVR: 0his system is highly reliable with least maintenance and is ideally suitable for gas driven generators. 0he static e*citation system was developed contemporarily as an alternative to brush less e*citation system. 0his system was successfully adapted to medium and large capacity 0urbo generators. 0hough the system offers very good transient performance the problems associated with slip rings and brush gear system are still present. 0his system consists of rectifier transformer thyristor converts field brea2er and 9,'. 0his system is ideally suitable where fast response is called for. 0he system is fle*ible in operation and needs very little maintenance.

0hus

each e*citation system has its own advantages and

disadvantages. 0he selection of system is influenced by the transient response required nature of pollution and pollution level in the power plant and cost of equipment.

E*citers are those components which are used for giving high voltage to the generator during the start up conditions. 0he main parts that are included in the e*citer assembly are8 C#D 'ectifier wheels C&D 0hree phase main e*citer C)D 0hree phase pilot e*citer C4D <etering and supervisory equipment RECTI#IER %HEELS: 0he main components of the rectifier wheels are 4ilicon 1iodes which are arranged in the rectifier wheels in a three"phase bridge circuit. 0he internal arrangement of diode is such that the contact pressure is increased by centrifugal force during rotation. 0here are some additional components contained in the rectified wheels. 6ne diode each is mounted in each light metal heat sin2 and then connected in parallel. Aor the suppression of momentary voltage pea2s arising from commutation '@ bloc2s are provided in each bridge in parallel with one set of diodes. 0he rings from the positive shrun2 on to the shaft. 0his ma2es the circuit connections minimum and ensures accessibility of all the elements.

THREE 'HASE 'ILOT EXCITER: 0he three phase pilot e*citer is a si*"pole revolving field unitJ the frame accommodates the laminated core with the three"phase winding. 0he rotor consists of a hub with poles mounted on it. Each pole consists of separate permanent magnets which are housed in non"metallic enclosures. 0he magnets are placed between the hub and the e*ternal pole shoe with bolts. 0he rotor hub is shrun2 on to the free shaft end. THREE 'HASE MAIN EXCITER8 0hree phases main e*citer is a si*"pole armature unit the poles are arranged in the frame with the field and damper winding. 0he field winding is arranged on laminated magnetic poles. 9t the pole shoe bars are provided which are connected to form a damper winding. 0he rotor consists of stac2ed lamination. =hich are compressed through bolts over compression rings. 0he three" phase winding is inserted in the slots of the laminated rotor. 0he winding conductors are transposed with in the core length and end turns of the rotor windings are secure with the steel bands. 0he connections are made on the side facing of the rectifier wheels. 9fter full impregnation with the synthetic resin and curing the complete rotor is shrun2 on to the shaft. AUTOMATIC VOLTAGE REGULATOR:

0he general automatic voltage regulator is fast wor2ing solid thyristor controlled equipment. It has two channels one is auto channel and the other is manual. 0he auto channel is used for the voltage regulation and manual channel. Is used for the current regulation. Each channel will have it3s own firing for reliable operation. 0he main features of 9,' are8 C#D It has an automatic circuit to control outputs of auto channel and manual channel and reduces disturbances at the generator terminals during transfer from auto regulation to manual regulation. C&D It is also having limiters for the stator current for the optimum utili!ation of lagging and leading reactive capabilities of turbo generator. C)D 0here will be automatic transfer from auto regulation to manual regulation in case do measuring -0 fuse failure or some internal faults in the auto channel. C4D 0he generator voltage in both channels that is in the auto channel and the automatically. COOLING SYSTEM: @ooling is one of the basic requirements of any generator. 0he effective wor2ing of generator considerably depends on the cooling system. 0he insulation used and cooling employed is inter"related. manual channel can be controlled

0he losses in the generator dissipates as the heat it raises the temperature of the generator. 1ue to high temperature the insulation will be affected greatly. 4o the heat developed should be cooled to avoid e*cessive temperature raise. 4o the class of insulation used depends mainly on cooling system installed. 0here are various methods of cooling they are8 a. 9ir cooling" :0<= b. Hydrogen cooling"#00<= c. =ater cooling +;00<= d. H & / =ater cooling + #000<= Hydrogen cooling has the following advantages over 9ir"cooling8 #. Hydrogen has % times more heat dissipating capacity. &. Higher specific heat ). 4ince Hydrogen is #7#4th of air weight. It has higher compressibility 4. It does not support combustion. &ISA&VANTAGES: #. It is an e*plosive when mi*es with o*ygen. &. @ost of running is higher. Higher capacity generators need better cooling system. 0he two"pole generator uses direct cooling for the rotor winding and indirect air"cooling for the stator winding. 0he losses in the remaining generator components such as iron losses windage losses and stray losses are also dissipated through air. 0he heat losses arising in the generator interior are dissipated through air. 1irect cooling of the rotor essential eliminate hot spots and differential

temperatures between ad5acent components

which could result in

mechanical stresses particularly to the copper conductors insulation and rotor body. Indirect air"cooling is used for stator winding. 9*ial"flow fans arranged on the rotor via draw the cooling air for a*ial"flow ventilated generator via. Lateral openings in the stator housing. Hot air is discharged via. 0hree flow paths after each fan. #LO% 'ATH "8 it is directed into the rotor end windings space and cools the rotor windings part of the cooling air flows past the individual coils for cooling the rotor end windings space via bores in the rotor teeth at the end of the rotor body. 0he other portion of the cooling airflow is directed from the rotor end winding space into the slot"bottom ducts from where it is discharged into the air gap via. 9 large number of radial ventilating slots in the coils and bores in the rotor wedges along these paths the heat of rotor winding is directly transferred to the cooling air. #LO% 'ATH $: it is directed over the stator end windings to the cold air ducts and into the cold air compartments in the stator frame between the generator housing and rotor core. 0he air then flows into the air gap through slot in the stator core where it absorbs the heat from the stator core and stator winding. #LO% 'ATH (8 It is directed into the air gap via. 0he rotor retaining"ring. 0he air then flows past the clamping fingers via. ,entilating slot in the stator core into the hot air compartments in the stator frame being discharged to the air cooler. 0he flow path mainly cools the rotor retaining rings the ends of the rotor body and the ends of the stator core.

Alow &/) mi* in the air gap with # leaving the rotor. 0he cooling air then flows radially outward through ventilating slots in the core within the range of the hot air compartments for cooling of the core and winding. 0he hot air is discharged to air cooler. OIL SYSTEM: Lubrication oil is to be supplied in order that the rotor can be easily ruined. Mac2ing oil is first given in order to shift the shaft near the 5ournal and so that it can be ruined easily. Mac2ing oil is given only at the starting and it is stopped and further lube oil is given continuously. 0his oil is to be continuously in order to reducing wear and tear on the bearing.

STATOR
T)e *ario+s losses in t)e ,enerator are broa-l. /lassi0ie- as belo1: " Iron losses7@ore losses7<agnetic losses7@onstant losses i2 H.sterisis losses ii2 E--. C+rrent losses $ @opper losses7 I,' losses7 winding losses. ( <echanical losses7 Ariction / windage losses. STATOR CORE: T)e 3+r3ose o0 t)e stator /ore is t1o 1a.s: #. 4upport the winding &. @arries the flu* 4o the selection of material for building up of core plays a vital role. 0he losses i.e.J magnetic losses are mainly two types. " Hysterisis Losses8 1ue to the residual magnetism in the material $ Eddy @urrent Losses8 1ue to the E<A produced in the core of the stator. In order to minimi!e the Hysterisis losses silicon alloyed steel sheets are used for building up of core.

0he sheets has the following composition 4teel 4ilicon Impurities " $;.;> "4> "0.&>

0he sheets are 4> 4ilicon 9lloyed @6L1 '6LLE1 ?6?".'9I? 6'IE?0E1 4HEE04 C@'?.6D. 0o reduce the Eddy @urrent Losses the core is build up of 0.;mm thic2ness laminations which are insulated from each other. 0he sheets are insulated by @L944"B type of varnish. LAMINATION 'RE'ARATION: 0he core is built up of : sectors each of :0N@ cut accordingly to the specifications. 0he cut steel is punched for slots and deburred up to ; micron. 1epending on the temperature withstand ability of the machine the laminations are insulated by varnish.

0he insulation used is 9LBO1 -HE?6LI@ ,9'?I4H dried at suitable temperature. 0he lamination sheets are passed through a conveyor which has an arrangement to sprin2le the varnish and a coat of varnish is obtained. 0he sheets are dried by a series of heaters at a temperature of around )00N"400N@. 0wo coatings of varnish are provided in the above manner. 0he thic2ness of varnish should be ("#0 microns when measured by a mini tester. Each lamination should be dried for around $0sec at constant speed. 0he prepared laminations are passed for various tests. iD Fylol test" for proper coat of varnish this test is made. =hen Fylem is applied for # min varnish should not dissolve. iiD <andrel test" when wound around mandrel there should be no crac2s. iiiD ,iscosity test" it should be 40"4; cp. ivD I' value test" for &0 layers the insulation resistance should have a minimum value of # <ega 6hm at &)2g7cm& pressure.

vD Hardness test + minimum %H pencil hardness the coating should not be removed when scratched with a %H pencil. viD Gniform test + coating should be done uniformly. CORE ASSEMBLY: " Trial /ore asse4bl.: 0hree pac2ets are assembled on the clamping plate and all relevant chec2s are carried out. @ritical chec2s are inside diameter of the core final inspection drift passage through the slot. 9fter fulfilling the entire above requirement the pac2ets are disassembled. $ Re,+lar /ore asse4bl.: 0he pac2ets assembly is carried out as per drawing requirement the segments are staggered from layer to layer so that a core of high mechanical strength and uniform permeability to magnetic flu* is obtained. 4tac2ing mandrels and bolts are inserted into the winding slots bores during stac2ing provide smooth slot walls. 0he length of each pac2et of laminations should be as per the design. Between each pac2et ventilation lamination sheets is assembled whose thic2ness is 0.:; mm and on which K IL beams is spot"welded. 0his provides the ventilation in radial directions

. ( Nor4al 3a/5ets asse4bl.: 0he above process is repeated up to (00mm after attaining (00mm first pressing is carried out as per drawing requirement. 9fter completion of the core assembly core lengths are chec2ed in ( to #& locations either in

cloc2wise or anti"cloc2wise direction if any variation in the core lengths is being noticed replenish the core height in subsequent final core assembly. 9fter completion of core assembly clamping plate is assembled. 9ll the core lengths are chec2ed around the outer/ inner diameter cloc2wise as per the drawing requirements. 4o under final pressure tension bolts are assembled and the core bolts are tightened with the specified torque. 0he clamping bolts running through the core are made of non" magnetic steel and are insulated from the core and the pressure plates. 0he pressure is transmitted from the pressure plates to the core by clamping fingers. 0he clamping fingers e*tended up to the ends of teeth thus ensuring a firm compression in the area of the teeth. ?ow first ring is welded on the both side under pressure similarly the subsequent ring are also welded. 0he total vertical core is shifted hori!ontally on e*citer side and again winding brac2ets are assembled and chec2ed for $0c as per the drawing requirements. 9fter completion of cleaning the total stator in all respects li2e filling lamination pro5ections sharp corners and interuption of foreign matter. 0hen the the stator is sub5ected for core flu* test to detect hot spots. @ON&UCTOR CONSTRUCTION: @opper coils are received and e*amined for physical and electrical properties in accordance to the specification. 0he conductors are cut in to require si!e as per drawing requirementJ this operation is called CON&UCTOR CUTTING ROEBEL TRANS'ORTATION:

0he strips are staggered and are bend for 'oebel transposition. 0he individual bars are transposed to ):0c equali!e the induced E<A in all strands to minimi!e the circulating currents and to reduce the s2in effect and it gives a good rigidity to the bars. 9fter alining both bottom dye and top dye conductors are pressed and chec2ed as per the drawing requirement and center to center length is been chec2ed first and second bundle are assembled together to form a single bundle and then an insulation sheet is 2ept in between two bars and they are 5oined together to form a single bar. 'UTTY %OR6: Each individual bar consisting of uneven surface and width space are filled with noma* and trivaltherom <ica fleece is placed on both the surfaces and further taping is done by -0AE tape C-oly tetra Aluro EthyleneD and are sub5ected for further processing.

STAC6 CONSOLI&ATION8
0he bars are sub5ected to a hori!ontal and vertical pressure of#;02gs7cmsquare at a temperature of #;0deg.c for the duration of & to ) hours. -assing gauges li2e no go gauges and go gauges and lamp test is conducted for inter strip and inter half shorts. #IRST 7 SECON& BEN& O'ERATION: Bending operation is done on bending table. Airst and second bend is carried out and to achieve the over hang third bend formation the coil is laid on universal former. 'oto pa* and harder is applied along with noma* in between two halves of the overhang portion and hence consolidation is carried out by 2eeping heating clamps. CLEANING AN& 'RE'ARATION O# BARS:

Bars are cleaned and tested for inter strip and inter half shorts and sub5ected for final tapping. #INAL TA''ING: Ta33in, is /arrie- o+t on t)e bars b. t1o 1a.s, t)e. are:! #. <anual tapping &. <achine tapping 'esin rich and 'esin poor insulating materials are characteri!ed by the contact of the Epo*y 'esin. In 'esin rich system the content of Epo*y 'esin is 40> in tape so it is named as 'E4I? 'I@H 4O40E< and in 'esin poor system the content of 'esin is (> in tape so named as 'E4I? -66' 4O40E<. RESIN 'OOR TA''ING: 'esin poor mica tape is used for resin poor barsJ the first layer is carried out by spreading the copper foils. 0hen :*#7& overlapping layers of resin poor tape is wrapped.0hroughout the length of the bar including )rd bend i.e. and &*#7& over lapping layers of resin poor tape is carried out only in straight portion one layer of split mica is warrped by spreading ocp at bottom such that their must not be any overlapp between split mica tape ultimately 6@is wrapped in the straight portion E@- is wrapped from the end of the straight part up to overhang second bend. 4tarting from straight portion upto )rd bend portion hyper seal tape is wrapped on both sides and sent for stator winding.

0ransition insulation + nome* glass fleece. Halves insulation ect. top bar" fine mica poly glass cloth. 6verhang separator coating" thoroughly mi*es rotopo* #:4 / hardener H $0 in ;8#ratio 0ransposition filler" micanite. Inner conductive tape + fleece tape with graphite 6uter carona tape" poly fleece tape End carona protection tape"fleece tape with silicon carbide -rotective tape for overhang" glass tape I@- " CInner carona protectionD " " " " " " " bars. " capacitance 0o dampen the voltage surges through additional surface 9lso @alled Inner potential grading on the stac2 of the bars to 0o optimi!e insulation they3re by voltage stress grading. -rovided with conductive fleece tape with a copper strip. 6n the outer surface of the insulated startor bars. @onductive fleece tape. 0o provide effective path for outer corona discharges. 4emiconductive tapes on both ends of the straight part of the avoid inner corona discharges.

6@- " Couter carona protectionD

E@-" Cend carona protectionD

RESIN RICH TA''ING: 9ll the operations relevant to 'esin -oor 0apeing are common up to overhang consolidation only final tapping is differed. In resin rich system i.e. #&*#7& overlapping of resin rich tape is wrapped over the resin rich bar and sub5ected for final ba2ing operation. 0he bar is heated up to $0c for the duration of :0 minutes. 0his stage is 2nown as .EL A6'<90I6? and again the bar is heated to ##0c with in the span of )0 minutes. 1uring this time the bar is tightened from the center towards the bend portion on both sides. 0his stage is 2nown as liquid formation from $0c to ##0c #;> of resin is oo!ed out and remaining resin is consolidated for duration of ) hours at a temperature of #:0c and allowed for natural cooling. In straight portion 2(((0 conductive coating is carried out and in bend portion semi conductive coating is carried out. 'ed gel paint is carried out in both the overhang portions. 0his process is repeated for each individual bar for the total number of bars required. 9nd H, and tan delta test is carried out for each bar.

STATOR %IN&ING: 0he three"phase stator winding is a fractional pitch two"layer type consisting of individual barsJ each stator slot accommodates two bars. It is a double layer lap winding with :0o phase spread fractional =indings are used to reduce higher order harmonics and pitch of the winding is so 4elected that ;th and %th harmonics are greater reduced. 0he slot bottom bars and top bars are displaced form each other by one winding pitch and connected at their ends to form coil groups. 0he coil

groups are connected together with phase connectors inside the stator frame. 0his arrangement and shape of the bars at the results in a cone shaped winding having particularly favorable characteristics both in respect of its electrical properties and resistance of only one turn insulation and main insulation identical. 4tator core received after the core assembly is chec2ed for the availability of foreign matter so coil pro5ections are chec2ed in each slot. H.L drift is passed in each and every slot to detect bottom core pro5ections. =inding holders are adopted and binding rings are assembled on both sides. 0he H.L binding rings are centered to the core and then bottom bars are laid. Each bar is pressed with a pressing fi*ture to obtain specified dimensions. By adopting this above procedure the entire bottom bars are laid in respective slots. 9fter completing of bottom bar layer reinforcing the overhang portion by tying with neoprine glass sleeve. 0emporary wedging is carried out H, testing is done and then stiffeners are assembled. 0op bars are laid by pressing each bar with a pressing fi*ture and all the bars are laid in respective slots. In between top and bottom bars H.L spacers are 2ept. 9nd then top bars are tested. Individual eye 5ointing and bracing is carried out. 0hen after eyes 5ointing individual eyes are insulated with fine mica tape. 9fter completion of eyes 5ointing connector rings are assembled / connected as per drawing and three neutral and three phases terminal are terminated out. 6nce again H, test is carried out before sending the stator to impregnation.

CONNECTION O# BARS: Bra!ing ma2es the electrical connection between the top and bottom bars. 6ne top bars strand each is bra!ed to one strand of the associated bottom bar so that beginning of each strands is connected without having any electrical contact with the 'emaining strands. 0his connection offers the advantage that circulating current losses In the stator bars are 2ept small. 0he strands are insulated from each other at the bra!ed 5oints. 0he coils connected are wrapped with dry mica7glass fabric tapes half overlapped. 0he thic2ness of the wrapper depends on the machine voltage. 0he gaps between the individual coil commendations being sufficiently large no additional insulation is required. 'HASE CONNECTORS: 0he phase connectors consist of flat copper sections the cross section of which results in a low specific current loading. 0he connections to the stator winding are of riveted and soldered tape and are li2e"wise wrapped with dry mica7glass fabric tapes. 0he phase connectors are firmly mounted on the winding support using clamping pieces and glass fabric tapes.

TERMINAL BUSHINGS: " ARRANGEMENT O# TERMINAL BUSHINGS

0he beginning and ends of the three phase windings are brought out from the stator frame through bushings which provides for high voltage insulation. 0he bushings are bolted to the stator frame at the e*citer end by their mounting flanges. Bushing type current transformers for metering and relating may be counted on the Bushings courtside the stator frame. 0he generator main leads are connected to the terminal connectors outside the stator frame. $ CONSTRUCTION O# TERMINAL BUSHINGS: 0he bushing conductor consists of high conductivity copper buses. 9ll connection flanges are silver"plated to minimi!e the contact resistances of the bolted connections. 0he supporting insulator of glass sil2 cloth is impregnated with epo*y resin. 0he copper buses are attached to the insulator only at one end and are thus free to e*pand. Ale*ible connectors allow for thermal e*pansion between the terminal bushing and the phase connectors. 0o prevent eddy current losses and inadmissible overheating the mounting flange is made of glass sil2 cloth as well. ( COOLING O# TERMINAL BUSHINGS: 0o dissipate the heat the terminal bushings are directly cooled with cold air. @old air form the discharge end of the fan is pressed in to the insulator. 0he hot air is returned to the suction in ta2e of the fan via the passage between the two copper buses.

ROTOR 0he rotor shaft is forged from a vacuum degassed steel ingot. @omprehensive test ensures adherence to the specified mechanical and magnetic properties as well as a homogeneous forging. 0he rotor consists of electrically active portion and two shafts ends. 9n integrally forged flange coupling to connect the rotor to the turbine is located out board of the bearing. 9ppro*imately :0> of the rotor circumference is provided with longitudinally slots which hold the field windings slot pitch is selected so that the two solid poles are displayed by #(0 degrees. 1ue to the non"uniform slot distribution is on the circumference different moments of inertia are obtained in the main a*is of the rotor. 0his in turn causes varying shaft deflections at twice the system frequency. 0o reduce these vibrations the deflections in the direction of the poles a*is and neutral a*es are equali!ed by the transverse slotting of the poles. 0he rotor teeth at the ends of the rotor body are provided with a*ial and radial holes enabling the cooling air to be discharged into the air gap after intensive cooling of the end windings. Rotor 1in-in,s Constr+/tion8 0he field winding consists of several series connected coils inserted into the longitudinal slots of the rotor body the coils are wound so that two poles are obtained. 0he solid conductors have a rectangular cross"section and are provided with a*ial slots for radial discharge of the cooling gas. 9ll conductors have identical copper and cooling duct cross"section.

0he individual conductors are bent to obtain half after insertion into rotor slots. 0hese turns are combined of from full turns the series connected turns of one slot constitute one coil the individual coils of the rotor winding are electrically series connected so that one north and one south magnetic pole are obtained. VENTILATION CONSUME 7 89 BEN&ING: Airst the conductors are chec2ed for their quality and ventilation holes are punched and they are chec2ed for burr. 0hen edge wise bending is made. 0he conductors are bent more than $0 o so that it will sustain spring bac2 effect. 1ebugging ventilation slots by relevant tools. ANNEALING: 0hen the conductors are heated and pressed at the bending so that the cross section of the conductors will be maintained equal through out. 0his process is called annealin, &OVETAIL 'UNCHING7%IN&O% &IMENSION: 9 small portion near the bend is removed so that it does not cause any damage to the insulation trough while lying in the slots. 0his process is called relief filing. 0hen dovetail punching is made which provides good bra!ing process when two conductors are 5oined. =indow dimensions for the conductors are chec2ed. 0he dimension of the window decreases from top to bottom conductors. CLEANING: 0hen the conductors are cleaned with thinner CacetoneD and then air"dry varnish is applied. 0hen 2eeping the conductors on a dummy rotor ma2es radial bending. Aor the conductors away from the poles prebra!ing is done.

Con-+/tor 4aterial8 0he conductors are made with silver content of appro*imately 0.#> as compared to the electrolytic copperJ silver alloyed copper features high strength properties at high temperatures so that coil deformations due to thermal stresses are eliminated. Insulation8 0he insulation between the individual terms is made of layer of glass fiber laminate with nume* filler. C)ara/teristi/s o0 /o33er to be +se- are: 1ensity <elting point 0hermal conductivity w7m"oc @oefficient of thermal e*pansion at &0 oc7oc 'esistively ohm "m 'esistance temperature coefficient at &0oc "#oc 4pecific heat M72goc ($002g7m) #0() );0 #:.%*#0": 0.0#%&4*#0"; 0.00)$) )$0

Arran,e4ents o0 ins+lation in la.in, o0 /o33er in t)e slots: 0urn insulation of glassofle* in straight part. 0urn insulation of glassofle* in overhang before bend. 0urn insulation of glassofle* at bends 0urn insulation of glassofle* in overhang after bend. 4hellac varnish -"(0 Insulating troughs. 0he connections for the coils on both the poles will be as follows8

'ole " TS

3ole $

ES :;2 Lo/ation o0 3arts in rotor 1in-in,: Rotor slot 1e-,es: 0o protect the winding against the effects of the centrifugal force the winding is firmly secured in the slots with wedges. 0hey are made from an alloy featuring high strength and good electrical conductivity and are also as damper winding bars the slot wedges e*tend below the shrin2 seats of the retaining rings the ring acts as short circuit in the damper windings. En- 1in,in, s3a/in,: 0he spaces between the individual coils in end windings are filled with insulating members the insulating members prevent coil movements and are used for intensive cooling of the rotor end windings. Rotor retainin, rin,s: 0he rotor retaining rings balance the centrifugal force due to the end windings. 6ne Pend of each rings is shrun2 on the rotor body while the other :!2

end of the ring overhangs the end winding without contacting on the shaft this ensures an unobstructed shaft direction of the end winding. 0he shrun2 on the hub at the free end of the retaining ring serves to reinforce the retaining ring and secures the end winding in the a*ial direction at the same time. 9 snap ring is provided for additional against a*ial displacement of the retaining ring. 0o reduce the stray losses and have high strength the rings are made up of non"magnetic cold wor2ed materials. @omprehensive test such as ultrasonic e*aminations and liquid penetrate e*amination ensures adherence to the specified mechanical properties the retaining ring shrin2"fit areas. 0hese act as short circuit rings to the induced currents in the damper system to ensure low contact resistance the shrin2 seats of the retaining rings are coated with nic2el aluminum and silver by a three step spraying process. #iel- /onne/tions: 0he field connections provide electrical connections between the rotor winding brush less e*citers. Ter4inal l+,8 0he terminal lug of a copper conductor of rectangular cross"section one end of the terminal lug is braced to the rotor winding while the other end is screwed to the radial bolt. Ra-ial bolt: 0he field current lead located in the shaft bore is connected to the terminal lug at the end winding through a radial bolt. 0he radial bolt is made from steel and screwed into the field current lead in the shaft before. #iel- /+rrent lea- in s)a0t bore8

0he leads are run in the a*ial directions from the radial bolt to the end of the rotor. 0hey consist of two semicircular conductors insulated from each other by an intermediate plate and from the shaft by a tube. Rotor 0an: 0he generator cooling air is circulated by two a*ial fans located on the shaft at both end two augment the cooling or the rotor winding the pressure established by the fan wor2s in con5unction with the air e*pelled from the discharged along the rotor. 0he moving blades of the fan have threaded roots for being screwed into the rotor shaft the blades are dropped forged from an aluminum alloy the threaded root fastening permits the blade angle to be ad5usted each blade is secured at its root with a threaded pin. BALANCING: 9fter rotor is manufactured rotor is balanced .It is desired that every rotor should run smoothly in its bearings. In order to achieve it the rotor should be balanced before assembling. 0he larger the rotor the more the balancing is required. Balancing of rotor is carried out in two steps #. 4tatic balancing &. 1ynamic balancing Stati/ balan/in,: In static balancing the rotor is put on two plain rails. 'ails replace the shaft at the bearing ends. 0he rails should be perfectly hori!ontal as possible. 0he rotor should be in position to swing on these rails without friction. 0hen the eccentric force is balanced. 0his static balancing is only useful to bring the center of gravity very near to the a*is of the shaft but for e*act balancing dynamic balancing is needed. &.na4i/ balan/in,:

It helps to find not only forced but also torques on the shaft when the machine runs. 0his method of balancing helps to balance the deviation of the a*is of center of gravity from a*is of rotation. 'otation is essential for dynamic balancing. 0urbo generators are generally dynamically balanced under rotor hot conditions. 0he weights on either side of the a*is of the rotor are determined. 0he centrifugal force on the bearings is measured and weights on either side of the a*is of the rotor are not the same then the difference of weights are added to the required side of the a*is. In this way the rotor is balanced. Aor obtaining the most accurate balancing it is to be carried out in the presence of vacuum.

INSULATION SYSTEM In Electrical <achines insulation is most important requirement to sustain high voltages and basically insulation is the heart for electrical machines. Insulation is the property which has enormous resistance to the conductivity that is basically the forbidden gap between valance and conduction bands are very large I.e. formic level very high in insulating materials .0he property of good insulating material is non"conductive to electricity and conductor for heat. 9 good insulating material needs the following properties. #. 0he basic function of insulation is to provide insulation to live wire or live wire to earth. &. It should be good conductor to heat and bad conductor to electricity. ). It should withstand the designed mechanical stress. 4. It should have good chemical and thermal resistively and environmental resistively. 9n insulator should satisfy the following properties for an electrical system are #. ELE@0'I@9L -'6-E'0IE4 &. <E@H9?I@9L -'6-E'0IE4 ). 0HE'<9L -'6-E'0IE4 4. @HE<I@9L -'6-E'0IE4 INSULATING MATERIALS8

Insulating materials or insulates are e*tremely diverse in origin and properties. 0hey are essentially non"metallic are organic or inorganic uniform or heterogeneous in composition natural or synthetic. <any of them are of natural origin as for e*ample paper cloth paraffin wa* and natural resins. =ide use is made of many inorganic insulating materials such as glass ceramics and mica. <any of the insulating materials are man"made products and manufactured in the form of resins insulating films etc. in recent years wide use is made of new materials whose composition and organic substances. 0hese are the synthetic 6rgano"silicon compounds generally termed as silicones. 9n ideal insulating material should have8 C#D High dielectric strength sustained at elevated temperatures. C&D High receptivity or specific resistance C)D Low dielectric hysterics C4D .ood thermal conductivity C;D High degree of thermal stability i.e. it should not determine at high temperatures. C:D Low dissipation factor C%D 4hould be resistant to oils and liquid gas flames acids and al2alis. C(D 4hould be resistant to thermal and chemical deterioration. CLASSI#ICATION O# INSULATING MATERIAL: 0he insulating material can be classified in the following two ways. I. @lassification according to substance and materials. II. @lassification according to temperature. @lassification according to substance and materials8 aD 4olids CInorganic and organicD EF8 <ica wood slate glass porcelain rubber cotton sil2s rayon ethylene paper and cellulose materials etc. bD Liquids Coils and varnishesD

EF8 linseed oil refined hydrocarbon minerals oils sprits and synthetic varnishes etc. cD .ases EF8 1ry air carbon dio*ide nitrogen etc. CLASSI#ICATION ACCOR&ING TO TEM'ERATURE:
@lass
O 9 E B A H @

-ermissible temperature
$0 #0; #&0 #)0 #;; #(0 9bove #(0

<aterials
@otton sil2 paper cellulose wood etc neither impregnated nor immersed in oil. 0hese are unsuitable for electrical machine and apparatus as they deteriorate rapidly and are e*tremely hygroscopic. @otton sil2 / paper natural resins cellulose esters laminated wool varnished paper. 4ynthetic material of cellulose base <ica asbestos glass fiber with suitable bonding substance <aterial of class B with binding material of higher thermal stability. .lass fiber and asbestos material and built up mica with silicon resins. <ica porcelain quart! glass Cwithout any bonding agentD with silicon resins of higher thermal stability.

INSUL ATING MATERIAL #OR MACHINES:

Na4e o0 Material #. 4amicatherm calmica glass"n mimica domica folium filamic novobond"s epo*y therm la*man isola calmicafle* 4amica fle* ,ectro asbestos C):;.0&7):;.)&D Cused in resin richD Epo*ide pepreg glasscloth -olyester resin mat/rope Ins+lation Class A S)el0 li0e :In 4ont)s2 At At $9 oC <o/ : #& A33li/ation

<ain insulation of stator bars

&. ). 4. ;. :.

H B7A

4 &

( (

6verhang insulation of motor coils at )rd bends of multi turn coil <ain pole coils of synchronous machines =inding holders and interhalf insulation Bar to winding holder/stiffner groove of support segment of clamping plate Interturn insulation of rotor winding

: :

#&

%.

.lassofle* 0urbo laminate

#&

(. $.

Hyper seal tape 4IB%%; or 4)0& varnish

A A A

: : : 4 4

#& #& #& ( (

#0. 4IB4%; or 4)0# varnish ##. 4IB :4) or(00) ,arnish or B(((: varnish #&. 4IB :4& or (00# varnish

9s finishing layer in overhangs of motor coils 4tac2 @onsolidation of stator bars Base coat varnish before taping of stator bars @onductive coat in straight portion of stator bars 9t slot emerge portion on stator bars

I. ELE@0'I9L -'6-E'0IE48
" INSULATON RESISTANCE8

It may be defined as the resistance between two conductors usually separated by insulating materials. It is the total resistance in respect of two parallel paths one through the body and other over the surface of the body. &. 1IELE@0'I@ 40'E?.0H8 0he voltage across the insulating and condition material. ). -6=E' A9@06'8 -ower factor is a measure of the power losses in the insulation and should be low. It varies with the temperature of the insulation. 9 rapid increase indicates danger. 4. 1IELE@0'I@ @6?409?08 0his property is defined as the ratio of the electric flu* density in the material .0o that produced in free space by the same electric force. ;. 1IELE@0'I@ L6448 0he dielectric losses occur in all solid and liquid dielectric due to CaD @onduction current material is increased slowly the way in which the lea2age current increases depend upon the nature

CbD Hysterisis.

II.

0HE'<9L -'6-E'0IE48 4pecific heat thermal conductivity. #. &. ). 4. ;. 0hermal plasticity Ignitability 4oftening point Heat 9ging 0hermal e*pansion.

III.

@HE<I@9L -'6-E'0IE48 #. 'esistance to e*ternal chemical effects &. 'esistance to chemical in soils ). Effect of water.

I,.

<E@H9?I@9L -'6-E'0IE48 #. &. ). 4. ;. :. 1ensity ,iscosity <oisture absorption Hardness of surface 4urface tension Gniformity.

E##CT O# MOISTURE ON INSULATION: 0hermal property @hemical property Electrical property -hysical and mechanical property. I?4GL90I6? 'E4I409?@E I4 EAAE@0E1 BO 0HE A6LL6=I?. A9@0I6' C'esistance between two conductorD8 #D It falls with every increase in temperature. &D 0he sensitivity of the insulation is considerable in the presence of moisture. )D Insulation resistance decrease with increase in applied voltage. E'OXY RESINS: 0hese resins are product of al2aline condensed of epichlorohydrin and product of al2aline condensed of epichlorohydrin and polyhydric compounds. -'6-E'0IE48 #D Epo*y resins have good mechanical strength less shrin2age and e*cellent dimensional stable after casting. &D @hemical resistance is high. )D .ood adhesion to metals. 4D 0o impact hardness certain organic acid anhydrides and alphabetic amines are mi*ed.

9--LI@90I6?8 #D 0hey are used in the manufacture of laminated insulating boards. &D 1imensional stability prevents crac2 formation in castings. )D 0hey are also used as insulating varnishes. E'OXY RESINS: Epo*y resins are poly ethers derived from epi"chlorohydrin and Bis"phenol monomers through condensation polymeri!ation process. In epo*y resins cross"lin2ing is produced by cure reactions. 0he liquid polymer having reactive functional group li2e oil etc otherwise vacuum as pre polymer. 0he pre polymer of epo*y resins allowed to react curing agents of low inductor weights such as polyamines polyamides polysulphides phenol urea formaldehyde acids anhydrides etc to produce the three dimensional cross lin2ed structures. Hence epo*y resins e*hibit outstanding toughness chemical inertness and e*cellent mechanical and thermal shoc2 resistance. 0hey also posses good adhesion property. Epo*y resins can be used continuously up to )00 A but withy special addition can withstand a temperature of up to ;00A. Epo*y resins are made use as an efficient coating material. 0his includes coating of tan2s containing chemicals coating for corrosion and abrasion resistant containers. Epo*y resins are made up of as attractive corrosion and wear resistant floor ware finishes. 0hese are also used as industrial flooring material. 0hey are also used as highways 4urfacing and patching material. <olding compounds of epo*y resins such as pipe fitting electrical components bobbins for coil winding and components of tooling industrial finds greater application in industries. 0he epo*y resins similar to polyester resins can be laminated and fiber reinforced CA-'D and used in glass fiber boats lightweight helicopters and aeroplanes parts. In the modern electronic industry the application of epo*y resins is great. -otting and encapsulation Ccoating with plastic resinD is used for electronic parts. <ost of the printed circuits bodies are made of lamination epo*y resin which light but strong and tough.

INSULATING MATERIAL FOR LAMINATIONS: 0he core stac2s in modem machines are sub5ected to high pressers during assembly and sub5ected to high pressures during assembly and there fore to avoid metal"to"metal contact laminations must be well insulated. 0he main requirements of good lamination insulation are homogeneously in thin layers toughness and high receptivity. =e use varnish as insulating material for laminations. VARNISH 0his is most effective type of insulation now available. It ma2es the laminations nest proofs and is not effected by the temperature produced in electrical machines varnish is usually applied to both sides of lamination to a thic2ness of about 0.00:mm. 6n plates of 0.);mm thic2ness varnish gives a stac2ing factor about 0.$;.In order to achieve good insulation properties the following processes are in BHEL. 0HE'<6-L940I@ -'6@E44 6A I?4GL90I6? 0HE'<64E00I?. -'6@E44 6A I?4GL90I6? BHEL is practicing only thermosetting process of insulation so 0hermosetting types of insulation are of two types8 'E4I? 'I@H 4O40E< 6A I?4GL90I6? 'E4I? -66' 4O40E< 6A I?4GL90I6? MATERIAL #OR RESIN RICH BARS8 -reprag ?ome* Epo*y resin rich mica tape .lass tape -0AE tape

VARNISH <ica powder .raphite powder @onductive varnish 4emiconductor varnish MATERIAL #OR RESIN 'OOR HAL# BARS E-6FO glass cloth ?ome* glass fleece Aine mica polyester glass cloth ?ome* Aorm micanite Aorm mica tape @opper foil -olyester fleece tape with graphite for I@ -olyester fleece for 6@ -olyester fleece tape with silicon carbide <ica splitting tape VARNISH -olyester glass tape 'utapo* Hardener CH"$0D MATERIAL #OR RESIN 'OOR &IAMON& COILS 0reated trivoltherm Impregnated polyester fleece .lass mat with accelerator Hostofon folium 4ynthetic fiber tape 'esin poor mica tape -olyester fleece tape with graphite 4emiconductor asbestos tape -olyester glass tape -olyester fleece tape ?ome* polyamide adhesive tape

RESIN RICH SYSTEM: In olden days 'esin 'ich system of insulation is used for all Electrical <achines. In insulator contains nearly 40> of E-6FO 'E4I? so it gives good thermal stability 'esin 'ich Insulation consists of the following materials in percentage #. <I@9 -9-E' 09-E "40";0> &. .L944 -9-E' 09-E"&0> ). E-6FO 'E4I?"40> 0he bars are insulated CorD taped with 'E4I? 'I@H 09-E and place in the -re"assembled stator core including stator frame. In resin rich system of insulation <ica paper will give a good dielectric strength and .lass fiber tape will give a good mechanical strength and Epo*y resin can withstand up to #;; degree @entigrade so it gives a good thermal properties. 'esin rich and 'esin poor insulating materials are characteri!ed by the contact of the Epo*y 'esin. In 'esin rich system the content of Epo*y 'esin tape is 40> so it is named as 'E4I? 'I@H 4O40E< and in 'esin poor system the content of 'esin tape is (>. By ,Iimpregnation process the required amount is added to then conductor bars after assembling the core and placing the winding in the core. In resin rich system before placing of coils in the stator slots the rich tape will be wrapped over the bars. ?evertheless this system has the following disadvantages8 #. 0his system is very time consuming and very long procedure. &. 0otal cost of the system is more.

In order to minimi!e the over all cost of the machine and to reduce the time cycle of the system the ,9@GG< -'E44G'E I<-'E.?90I6? 4O40E< is being widely used. 0his process is very simple less time consuming and lower cost. BHEL HO1E'9B91 is equipped with the state of the art technology of VACUUM 'RESSURE IM'REGNATION

VACCUM #RESSURE IM#REGNATION :

.E?E'9L8 &r MEYER brought the ,-I system 1it) the collaboration of =E40I?. H6G4E In the year #$;:. 0he resins used were of -olyester 4IE<E?4 developed ,-I system with Epo*y resin and treated accelerator on tapes. 0he <ica tapes used for ,-I 4ystem are '6.&%; '6.&%;.# and '6,&$& tapes with glass cloth bac2ing up to #).(B, voltage level. '6,&$& mica papers are with polyester fleece above #).(B, <achines. 0he advantage of fleece is for better and more penetration of resin. '6.&%;.# tape is special glue varnish for tropical countries li2e I?1I9 / Bra!il to resist higher humidity. 0he glue being used for main insulation tape is F&0&: and for conductor insulation is F&0&%. ,-I system can be useful for manufacture of insulation and also windings are guaranteed to e*pected quality. BHEL Hyderabad had installed the state of the art technology of ,9@@G< -'E44G'E I<-'E.?90I6? 4O40E< for cage stators up to #&;<=. @apacity which is the largest of it3s 2ind in I?1I9. 0his system conforms to the latest insulation system adopted by 6%U!SIEMENS

technology. 0he stator coils are taped with porous resin poor mica tape before inserting in the slots of cage stator subsequently wounded stator is sub5ected to a special ,-I process in which first the stator is vacuum dried and then impregnation in a resin bath pressure of nitrogen gas. 0hen the stator is cured in an oven.

0he main characteristics of this insulation system are8 # Better heat transfer resulting from penetration into minute air gaps in between laminations and bar insulation & Low dielectric loss resulting in increased life of insulation and so the machine. ) High resistance against the effect of moisture 4 'eduction of time cycle of insulation 0he resin used for ,-I is E0((4 a mi*ture of epo*y resin E#0&) Clee2utherm* #(D and hardener H#00: in #8#.& ratios by weight. In two components are mi*ed in #8# ratio. E#0&)8 0he resin is in drums of &&0 Bg by weight. It is in crystal from at temperature of .4 or &0@. 0he conductor is not completely filled with resin in practice #$0 or &002g. 'esin is available in the drums. 0he resin is heated in the furnace the resin is liquid state shall not come out of the container the drums are 2ept in oven and heated up to #00 for about #( hours. Every drum is to weight and loo2s into the resin for its state of condition before and after heating. If the resin is not fully in liquid condition can be heated uQp to #&;c. the storage tan2 is with resin first depending on the volume and ratio of mi*ture at temperature of :0c through nose pipes. 'esin filling is being done by creating 0.& bar vacuum in the tan2. RESIN MANAGEMENT: @hemical structure of resin used in resin tan2 0he resin tan2 contains the mi*ture of resin I Hardener I catalyst for good insulation system.

'E4I?8 0he chemical name of resin is BI4-HE?6L"9 . it is also called as 1iphenol propane. 0he chemical structure of diphenol propane is 1iphenol propane is also called as BI4-HE?6L"9 which also called as 'E4I? HAR&NER: It is used to solidify the resin. Hardner used in chemical @ompositions is 9?HO1'I1E is nothing but removal of water molecule CH&oD from a compound. Let us consider the anhydride of H&464 H&464" H&6 """""R 46) 46) is anhydride of h&so4 which is used as H9'1?E'. @909LO408 @atalyst is used to accelerate the rate of chemical reaction among resin and hardener. 0he @atalyst used in the process is SI?E ?9-0HE?E. Sinc ?apthane """"R Sn&@#0H( 0he mi*ing of ratio of resin is ;08;0 parts. ?o warming up of hardener is required. 0he resin mi*ture required for the BHEL impregnation tan2 is $000Ltrs * ;. SI=E O# THE TAN6: 0he si!e of the tan2 is 4000mm diameter / $000mm in height. IM'REGNATION CIRCUIT: 0hree storage tan2s of each resin capacity $000. in the operation for stirring the resin mi*ture cooling and heating cycle is by circulating the

resin through heat e*changers. Brine solution heated by steam is being used heat e*changers. 'RO'ERTIES O# MICALASTIC: 0he <icalastic post" impregnation process ensures a mechanically firm bond between all winding components and between the winding and the stator which is capable of with standing the various temperature rises occurring during operation. 0he micalastic system thus provides for reliable insulation is applied continuously from end to end stator bars providing effective protection against over voltages arising during normal operation and against the high stresses that may occur at the slot ends when high test voltages are applied. #. <icalastic has a long electric life as determined on hundred of e*periments bars and numerous full" si!e bars. &. <icalastic is a good conductor of heat by reason of its high mica contents and the void free synthesis resin. Efficient heat transfer is particularly important for dissipating of the copper losses in machines the require thic2 insulation because of the high voltage and are not designed with direct cooling winding. ). <icalastic features a high thermal stability the resin impregnation and cured insulation permits the machine to be operated continuously under condition corresponding to those for class A insulation. 4. <icalastic insulation shows only a small dissipation factor tip"up with increasing temperature which is also affected by the loss attributable to the grading material applied at the slots ends. ;. <icalastic features an elastic response to thermo"mechanical stresses. 9lternated heating and cooling with large difference in the temperature are endured without detrimental effects on quality. 0he micalastic insulation remains firmly bonded to the copper conductor and stator. 0he confirmed by the dissipation factor measured with rising voltage within the operating temperature range.

:. <icalastic owes its insensitivity to high temperature and temperature changes to the cured synthetic resin. 0his favorable performance under thermal stress is particularly advantages for machine sub5ect to frequent load changes e.g gas turbine or pea2 load generator in steam power plant drives generators. %. <icalastic does not burn. 0he insulation features such a low flammability that even on arcing it does not continue to burn once the has been e*tinguishing. Aire e*tinguishing systems such as @6 & bottle rac2s are therefore not necessary for <icalastic"insulated windings. (. <icalastic provide protection against moisture due to its impregnation with synthetic resin which seals the winding completely. $. <icalastic is highly resistant to chemical action. @orrosive gases vapour lubricating oil wea2 acids or al2alis to witch the winding may be e*posed under unfavourable conditions do not attac2 the insulation the impregnating resin does not react with chemicals. ?60E8 " Sinc napthanate is used as an accelerator in the resin poor system of insulation. It helps in fast curing of resin in case when repair is carried out on a 5ob which already has been to the impregnation plant. ALEE@E C?on wovenD /Aabrics8 -olyester fleece polyester tissues and flass tissues have a good absorption capacity for impregnating agents. 4urface insulating materials Cmulti layer insulation materialsD with considerably improved mechanical and electrical properties can be produced by combining with plastic film.

,9@@G< -'E44G'E I<-'E.?90I6? I?4GL90I6? -'6@E448" Here in BHEL they are using Hori!ontal impregnation chamber for higher capacity stators of 4team 0urbine CorD .as turbine .enerator and vertical impregnation chamber for smaller capacity systems such as -ermanent <agnet .enerator stators for brush less e*citation systems coil insulation of small pumps and armature of motors etc. In the following steps vacuum pressure impregnation of stator winding has been done. #. -reheating &. ,acuum cycle ). 1rop test 4. Heating the resin ;. 9dmission of resin in to tan2 :. -ressure curing %. @oating the 5ob (. -erformance tests. -'EHE90I?. 0HE M6B8 0he completed stator is placed in impregnation vessel and 2ept in an oven for a period of #& hours at a temperature of :0c.4i* thermocouples are inserted at the bac2 of the core to measure the temperature. 0he temperature should not e*ceed to (; c. 4maller stator can be installed directly impregnation chamber.

VACCUM CYCLE: 0he preheated 5ob ne*t will be placed in the impregnation chamber by a hydraulic mechanism. 0he vessels are 2ept clean 'esin available in the vessel is wiped out methlyne and traces of 'esin shall not be allowed on the inner side of the tan2. It reacts with humidity and scale formation will ta2es place these pieces at the time of main 'esin flow will mi* and bloc2 the penetration of resin into component and obstruct the filters also. 0he resin at the place of cleaning is carefully removed by wiping with rubber sheets. Beeping the vessels in slant position on the ground also cleans the inner vessels. 9fter the ensuring the perfect cleaning the tan2 should be allowed for further operations. 0he impregnation vessel containing preheated 5ob will be placed in the impregnation chamber. 0he lead of the chamber is allowed to close by hydraulic motor. 0he side temperature of the impregnation chamber should not be less than :0 @. 0he inside temperature was measured by placing the thermocouples at the bac2side of the core. 0he cooling and heating of the impregnation chamber was done through heat e*changers. 0he fluid used in heat e*changers is Brine solution. 0he lid of the chamber was closedJ silicon grease is applied on the surface of the chamber where the lid is touching. 9 rubber gas2et is also provided on the rim not to allow any lea2age. 9ir pipes are closed and vacuum pumps will be started ,acuum is created so that the dust and the moisture are removed Arom the 5ob if any. 0he total stator is sub5ected for vacuum cycle. 9fter 6btaining 0.& miilibar the total stator is sub5ected for #% hours then vacuum drop test.

0he most important factor considered is that during the manufacture and operation of the generator it greatly affects the dielectric strength of insulation &RO' TEST: In this test all the vacuum pumps are stopped and chec2 the vacuum drop it should not be greater than 0.0:mbar.

'E4I? HE90I?. 9?1 'E4I? I?LE08 'esin is stored in the tan2s at a temperature of #0 oc. 'esin tan2s are always agitated for ) min frequently every # hr other wise resin / hardener will get separated. 0his is heated upto :00c by using brine solution. Brine solution is a mi*ture of :0> water and 40> glycol. 0his mi*ture increases boiling point and reduces corona and decreases free!ing point when resin is cooled using this solution. 'esin mi*ed with hardener in equal proportions. 'esin is stored in the tan2s of ;T$000I#T)000 its. In this process the resin filling in the vessels and ta2en bac2 to the resin tan2s is done by the pressures difference inside and outside of the chamber. 0he impregnation vessel is filled with resin by pressure difference the resin in the resin tan2 is at atmospheric level and chamber is maintained at a 0.&m bar pressure the resin flows from higher pressure to lower pressure to lower pressure. 4o no pumps are required to fill the resin into the impregnating vessel. 0he resin filling is being completed in &; + )0 minutes. 1uring this time there is a change in pressure inside the chamber this should not be less than 0.0:m barsJ the vacuum will be created inside the chamber up to 0.&m bars.

0he level of the resin in the impregnating vessel should be #00mm above the 5ob. 0his can be seen through the mirrors arranged above the chamber otherwise there is a control and record of this resin in control room.

'RESSURISATION O# >OB: ?itrogen gas is sent at a pressure of 4 2g7cm& bar so that gaps if any left will be filled by 'esin. Aill the resin in the impregnating vessel up to #00mm above the 5ob. 0he resin is to be allowed to settle for #0 + #; minutes. 0he total 5ob is flooded with epo*y resin with the hydrostatic pressure of the resin only surface of the insulation can be filled with resin. 0o have an effective penetration up to the end of the copper barrier pressure is to be created to 4 bars by sending nitrogen gas in to the chamber. It could be maintained constantly for ) hours. RESIN 'UM'ING BAC6 TO THE RESIN TAN6: 0he resin is pressuri!ed as per the pressure cycle by which the opening of the valves will allow the resin to combine to the storage tan2. 0he 5ob also shall be allowed for about #0 minutes. 'esin which is ta2en inside the tan2 is first cooled with water and then by using chillers. 'OST CURING: 9fter completion of all the above operations the 5ob is to be post cured. 0he process of the post curing is carried out at #40 @ for duration of )& hours. In order to avoid unpolymarised resin. Beeping the 5ob in a furnace does this heating. 0he fuel for this furnace is producer gas. 'ollers are needed for rotating the 5obs so that any drips of resin will settle there it self. Aor smaller 5obs no rotation is needed. 'ed gel is sprayed on the 5ob after ta2ing it away from hot air / after circulating air and bringing its temperature to 40o to :0U. Hence the red gel stic2s to it finely and it offers smoothness to the surface of the 5ob.

IM'REGNATION 'LANT: Hori?ontal C)a4ber -i4ensions: Inner diameter Length ,ertical 1imension8 Inner diameter Length 8 #:00mm 8 )0(0mm 8 4000mm 8 $000mm

IM'REGNATION ME&IUM: Epo*y resin Hardener 6perating -ressure 0emperature 'esin storage capacity @harge =eight C+rin, O*en: 0emperature Heating <edium <a* weight 8 #40 to #%0c 8 @irculating hot air 8 #&00. 8 solvent tree class A79raldite <O"%$0 8 B1 ##0& 8 :Bars ?itrogen 8 $0c 8 ;* $000 Ltrs. 8 #&00.

@UALITY CHEC6S ON RESIN MIXTURE IN RESIN 'OOR 'ROCESS: 0he resin mi*ture is a combination of epo*y resin and hardener. 0he containers of resin and hardener are stored in a cool dry place. 0hey are closed until processing for protecting against humidity. 0he impregnating resin mi*ture in the ratio of #00 parts of epo*y resin is mi*ed to #00 parts of hardener in a resin tan2 of the impregnation unit. 0he epo*y resin and hardener heated in an oven at #&;@ and sample is ta2en from every drum to test before release. 0he resin mi*ture is sensitive to moisture and therefore it is stored under vacuum below &0@ but chilled not below (@. 9fter thorough mi*ing the resin mi*ture is tested. TEST ON RESIN MIXTURE: Before beginning impregnation and after stand still period of more than five days. 0he resin mi*ture is tested in the following manner. #. 0he resin mi*ture is tested for viscosity at :0 c and limiting value of viscosity is ;0m poise above which the resin is re5ected. &. 0he resin is again tested for the increase in its viscosity at :0 c after &0 hours heating at #00cJ the ma*imum value at this point is $m poise. ). 0he resin is then heated for its saponification number whose specified value is ))#."I) mg72oh7gram. 4. 9fter this test for the ester number which is the between saponification number and total acid number. Its ma*imum limiting value is #0. In case it e*ceeds #0 necessary addition resin or hardener is done. 9ccording to saponification number the resin mi*ture is released after each test for use.

TESTING 'ER#ORMANCE O# RESIN 'OOR SYSTEM:

BEA6'E I<-'E.?90I6? -'6@E448 0he different test which are carried out laying the bars in the stator slots. 0hey are8 #D @ompletion bottom layer high voltage test. &D @ompletion top layer high voltage test. )D =inding resistance measurement. #. B6006< L9OE' 0E40 9fter laying the bottom bars high voltage test is conducted with #.; G- for &minute where GpH &GnI# G-" Ainal test voltage Gn"'ated voltage of generator. &. 06- L9OE' 0E408 9fter laying the top bars high voltage test is conductor with #.# Gp for # minute where GpH&Gn"Ainal test voltage of generator. ). I?0E' @6??E@0I6? @HE@BI?.8 9fter completion of connection winding and ba2ing high voltage is conducted with #.0; Gp for #minute when one phase is under testing the other phases are earthen measurement of resistance of individual phases give the chec2ing of interconnection. 4. 9.@ HI.H ,6L09.E 0E408 9fter laying top and bottom bars high voltage test with 9.@ is carried out by connecting all other to ground. ;. <E@H9?I@9L 'G? 0E408 1ynamic test carried out to find various losses they are #. <echanical losses &. Iron losses

). @opper losses A#TER IM'REGNATION: 9fter impregnation of the stator core by ,-I following tests are conducted8 #. 09? 0E40. &. HI.H ,6L09.E 0ests. 09? 0E408 9fter impregnation and curing of the winding a dissipation factor ,s voltage measurement as stipulated in the application national and international standard specification is performed for each bar between all" individual phase winding to ground. .uiding values for the deception factor and its rice with the voltage merely. .iven in the BE<9 specification the ma*imum value shell not e*ceed 0.00# at &0> of rated voltage and rise shell not be greater than 0.00: per &0> of rated voltage up to :0> of rated voltage and 0.0( per &0> of rated voltage up to a rated voltage. =inding manufacture by the ,acuum -ressure Impregnation -rocess comply with these limits. 0he above test results are specified in the following graphs. Airst graph shows that voltage ,s 0an curve it shows different 0an values at different percentage of rated voltage &0> 40> :0> (0> #00> of rated voltage respectively. 0he second graph is a electrical field ,s life of insulation material it shows that resin poor system of insulation has very long life compared to resin rich system of insulation. 9t #0 B, the resin poor system insulation as a lifetime of ;40 years. 9ny good machine as life span of &;")0 years by using this insulation we will get a very long life with standard machine. process the

HI.H ,6L09.E 9@ 0E408 9 @ High voltage test is conducted on ,-I system after impregnation to verify proper impregnation and dielectric strength of insulation. 0his test was conducted at #0;> of winding test voltage i.e. GpH&GnI#B, =here Gp"=inding test voltage Gn"rated voltage of machine.

A&VANTAGES O# RESIN 'OOR SYSTEM O# INSULATION C#D It has got better dielectric strength C&D Heat transfer coefficient is much better C)D <aintenance free C4D It gives better capacitance resulting in losses due to which the insulation life will be more C;D 0he cost is less and it is the latest technology C:D 'eduction in time cycle and consumption <= is also less and it gives high quality &ISA&VANTAGE O# RESIN 'OOR SYSTEM: C#D 1ependability for basic insulation materials on foreign countries C&D If any short circuit is noticed the repairing process is difficult 91,9?09.E4 6A 'E4I? 'I@H 4O40E< 6A I?4GL90I6?8 #. Better quality and reliability is obtained. &. In case of any fault C-hase to ground CorD phase to phase shortD @arrying the repair process is very easy.

). 9ddition of e*cess resin will be avoided because of using resin 'ich mica tape. &ISA&VANTAGES O# RESIN RICH SYSTEM O# INSULATION: # & ) It is a very long procedure. 1ue to fully manual oriented process the cost is more. It is possible to process stator bars only.

COM'ARISN BET%EEN RESIN 'OOR AN& RESIN RICH SYSTEM RESIN 'OOR SYSTEM #. &. ). 4. ;. :. 0he insulation tape used in this system has (> of resin. 0hese method follows thermo" settling process. 0here is a need for addition of resin outside. 'eduction in time cycle for this process. ?o tests are carried out while at processing stage. -rocessing of bars along with stator processing of e*citer coils along with e*citer are possible in resin poor. ).Aurther addition of resin is not required from out side 4 It is very long process and time consuming. ;.0ests are being carried out while at processing stage. :.-rocessing of stator bars only possible in resin rich system. RESIN RICH SYSTEM #.0he insulating tape material used in this system has 40> resin. &.It as in resin poor.

%. (

0he cost of repairs is more. 0he over all cost is less compared to resin rich system.

%. (. more.

'epairing wor2 is easy. 0he total cost in this process is

9--LI@90I6?48 #D 9ll critical machines &D Equipment e*posed to frequent surges )D Harsh or moist environment 4D <otors that run at service factor ,-I -'6@E44 @6?0'6L8 0hroughout the ,-I process computer to endorse homogeneous resin fill continuously monitors each stator. #D Ensure uninterrupted power supply &D 9dhere to the process strictly. )D 9ssessments of critical failure in the system that can occur during process and it emergency preparations.

ASSEMBLY O# STATOR AN& ROTOR:

4tator and rotor after their manufactured and tested they are brought for assembly. 'otor is inserted into the stator using a crane and the following are chec2ed Bearing shell Id measurements Bearing shell blue matching 0op and bottom blue matching of bearings Mournal diameter Bearing shell / bedding top / bottom 4tator alignment trough centering 9ir gap TESTING O# TURBO GENERATORS: 6BME@0I,E 6A 0E'40I?.8 0esting is the most important process to be conducted on a machine after it is designed. 0he testing of machine is necessary to establish that the machine performance complies with the customer specification. performing duty for which it is intended. 0esting is done under conditions simulating as closely as possible to those which will apply when the set is finally installed with a view to demonstrate to purchaser3s representative its satisfactory operation test provides the e*perimental data li2e efficiency losses characteristics temperature limits etc for the use of design office both as conformation of design forecast and also as basic information for the production of future designs. 0ests ensure that the piece of equipment concerned is suitable for and capable for

I?0'61G@0I6?8 =ith ever increasing rating of the modern turbo generator and reliability of service e*pected testing manufacture3s wor2s has become of paramount importance. 0he machine performance is evaluated from the results of the equivalent tests. 91,9?09.E 6A 0E40I?.8 #. -rovide data for optimi!ation of design &. -rovide quality assurance ). <eets the requirement of legal and contract requirement 4. 'eduction in rewor2 cost ;. Ensure process capability and develops chec2list :. Increase confidence level in manufacture %. Establish control over raw materials. -E'A6'<9?@E 0E4048 0he performance tests on the turbo generator are classified as8 #. 0ype tests &. 'outine tests ). Heat run tests In our pro5ect we are doing only with 'outine 0ests. '6G0I?E 0E4048 0hese tests are carried out on each generator to ascertain that it is electrically and mechanical sound. 0hese tests are carried out on different machines / are classified as8

#. 4090I@ 0E408

 <easurement of Insulation 'esistance of stator / 'otor winding before /after High ,oltage test C<7c at testD High voltage test on stator / rotor winding C<7c at restD <easurement of polari!ation inde* of stator windings. &. 'G??I?. 0E408 <easurement of <echanical losses short circuit characteristic and losses <easurement of <echanical losses 6pen circuit characteristic and losses <easurement of rotor impendence Crotor inside statorD 4090I@ 0E404 <easurement of insulation resistance of stator / rotor winding before and after High voltage test8 Equipment8 CaD <egger C#0007&;00vD CbD Ear thing 'od earthing wire7 c able T I' of the stator and the rotor winding are measured separately before and after H, test using <egger of &;00, for stator / #000, stator windings. 0he values are ta2en at #; sec and at :0 sec. T 9bsorption coefficient of insulation is found out as Absorption coefficient= #'at:0 # 'at#; 0his value should beR orH & If I' values are quite high the absorption coefficient is not considered because of early saturation Coften observed in low voltage winding li2e rotor

etcD. =ith dry winding its value will be some where in the vicinity of & or even more. =ith damp winding it winding it will decrease to one. 9bsorption coefficient of #.( / #.% may be satisfactory while a value below #.; indicates a damp machine. T <inimum I' value 0he minimum value of insulation resistance C'mD at :0min is recommended as8 'm HC BvI#D ohms. =here B, is voltage in 2ilovolts to be applied for tests. In practice a fairly high value is obtained. 0he winding is discharged to earthy after each measurement & <easurement of polari!ation inde* of stator winding8 0he polari!ation inde* of stator winding all the three phases together is measured using &;00v megger after H, test. 0he I' values are noted at # min and #0min from starting of measurement. 0he -I is evaluated as follows -olari!ation inde* C-.ID H I.'. ,alue at #0min7I.'. value at # min 0he minimum allowable -I value is &.0 ). Hi,) Volta,e test: Equipment T;0 H! 9.@ High voltage transformers and its induction regulator7input autotransformer. T -otential transformer C); or#00B,7#00,D T ,oltmeter TBinding wire

T Earthing 'od and Earthing wire7cable =hen H., test is done on one"phase winding all other phase windings rotor winding instrumentation cables and stator body are earthed. 0he high voltage is applied to winding by increasing gradually to required value and maintance for # minute / reduced gradually to minutes. 0he transformer is switched off / winding discharged to earth by shorting the terminal to earth using earthing rod connected to earth wire7cable. 0he test is conducted on all the phases / rotor winding separately. H, 0est Levels8 4tator winding8 C&GtI#D B, H&) for ## B, machine 'otor winding8 C#0 GpD volts Cwith min of #;00v / ma* of );00vD =here GtH 'ated of machine under test GpH E*citation voltage.

'G??I?. 0E408 #. <easure of mechanical losses short circuit characteristic and losses8 T 0he machine is prepared for short circuit characteristic using current transformer and shorting lin2s T 0he machine is run at rated speed and drive motor input voltage and current are noted and machine is e*cited T .radually in steps at &0> 40> (0> $0>/#00> In. CIn8 rated current of machineD T 9t each step the following parameters are noted aD 4tator current CIa/IbD bD 'otor current CIfD corresponding to stator voltage. cD 1rive motor voltage CvdD and current CIdD corresponding stator voltage T 0he e*citations is reduced and cut off the speed is reduced and the machine is cooled at lower speed. 0he machine is stopped when it is sufficiently cooled down Cstator core temperatures to be less than :0 cD Arom the above data characteristic curves are plotted as follows8 aD >In v7s If bD >In v7n machine losses in 2w &.<easurement of mechanical losses open circuit characteristic and losses8 T 0he machine is run at rated speed and drive motor input voltage and current are noted and machine is e*cited gradually in steps at &0> En CEn8 rated voltage of machineD T 9t each steps the following parameters are noted aD 4tator voltages C,ab ,bc / ,caD

bD 'otor current CifD corresponding to stator voltage cD 1rive motor voltage C,dD and current CIdD corresponding stator voltage. 0he e*citation is reduced and cut off the speed is reduced and the machine is cooled at lower speed. 0he temperature are chec2ed from machine is stopped when it is sufficiently cooled down Cstator core temperature to be less than :0cD T Arom the above data characteristic curves are plotted as follows8 aD > En ,74 If bD > En v7s machine in Bw. ). <easurement of rotor impedance C'otor inside statorD T Equipment8 aD ;0HS Cpower frequencyD a.c.source bD 9c71c power analy!er cD @urrent transformer C;097;9 or #009D dD @onnecting leads 9 variable ;0H! 9.@. voltage of # is applied across the slip rings 7input leads and readings of voltage and current are noted down from ;0, to &00, in steps of ;0, 0his test is done at #7) &7) and at rated speed Evaluation of Impendence8 SH ,7I ohms =here S H impendence in ohms ,Hvoltage I H @urrent

Impendence measurement8 #. 9t rated rpm C'otor inside statorD &. 9t standstill C'otor inside statorD ). 9t standstill C'otor outside statorD TAN TEST: Equipment8 4chering Bridge 0his test is conducted to chec2 the presence of impurities in the insulation / tan value for each phase / also for combined phases is noted down. 0an value should be generally less than or equal to &>. TESTING RESULTS: ,ph C0.&Gn D 'ated B,H #0.;B, )000'-<. Gph &.# 4.& :.) (.4 #0.; =ph &.# 4.& :.) (.4 #0.; 0an 0.(#; 0.()& 0.(:$ 0.$0) 0.$)( 0an 0.(0: 0.(&0 0.(;% 0.($$ 0.$4#

,ph &.# 4.& :.) (.4

0an 0.(## 0.()0 0.(:( 0.$0;

Gph ,ph =ph &.# 4.& :.) (.4 #0.;

0an #.#( #.&0$ #.&)0 #.&;4 #.&:(

'ating8 )#.&; &;0 <= ##B, #:409 0.(pf )000rpm. 4@@8 Ia 0 ))%.& ::4.( #00;. ( #)&4. $ #4$;. & 6@@8 ,ab ,bc ,ca >En If ,d Id 1m Ib 0 ))%.: :::.& #00:.# #)&:.; #4$:.$ >In 0 &0.;% 40.; :#.)4 (0.(4 $#.& If 0.0# $4.% #(%.# &(#.;# ):$.#: 4#;.& ,d ;;$.0 ;#;.$; ;#:.04 ;#:.;& ;#:.;4 ;#:.#( Id 404.;( 44).# 4(#.4 ;)).: :;#.&; :$0.) 1m 67&&:.#: &&(.:0 &4(.44 &%;.: )):.); );:.)&

);.) &&(#.& 444%.4 & :::&.0 ((4;.0 #00#;. 0

);.) &&(&.; 444#.4 :::;.0 ((4$.0 #00#$. 0

);.) &&(#.( 444(.& :::).0 ((4:.0 #00#%. 0

);.)& &0.%4 40.44 ::.;( (0.4 $#.0:

0.0# 40.44 %%.0; ##:.:; #:0.) #(:.;:

;#&.4 ;#&.$) ;#&.4 ;#&.) ;#&.#$ ;#&.&;

4#$.(; 4&).#; 44&.4; 4::.4) ;0#.0( ;#%.&;

67&#;.#: &#:.:& &&:.%# &((.$; &;:.:4 &:4.$)

'esistance <easurement8 Instrument8 <icro ohm meter 'otor 'esistance at &;c CmD &:4 'esistance at &0c CmD &;(.$&

'%; H CC &);I%;D7C&);I&0DD * '&0H C)#07&;;D * C0.&;(%DH0.)#4% 'otor current H ;:& 9 Efficiency H CoutputD7CoutputIlossesD Losses H $$.;)& I $.$;)& I )$.)$ I )(;.#; I &(:. )( H (&0.40 EfficiencyH C&;0007&;000 I (&0 .40 D H $:.(&>

,ON,LUSION8 @onsidering the manifold advantages of ,-I 4ystem of insulation the leading manufacturers of =orld are going to adopt this system for generators up to 400 <= with hydrogen gas cooling. It has better thermal electrical mechanical and chemical properties and its life time is about ;4o years. In view of the above in the coming decades the Indian grids will use more of such generators. In the scenario of =orld mar2et which demands generators with less cost at the best possible time with better reliability ,-I system of insulation will provide most viable solution.

B I B I L O G R A P & Y8 #. &. ). 4. ;. E!e"tri"a! Ma"'ine.: E!e"tri"a! De.i/n0 O%eration an( Maintenan"e Man$a!.: En/ineerin/ ,'e i.tr#: E!e"tri"a! in.$!atin/ Materia!.: E!e"tri"a! Ma"'ine.: '.B.Batta @harya BHEL Hyderabad 1aniel Oesudian '.B.'a5put <...4ay