A Technical report on the study of

Manufacture & Assembly of Turbo Generator

Training Incharge: Submitted By:
Mr.Rajendra Kumar Manish Snehi
Proj. Guide: Mr. S K Singh Enroll. No.-11115051
Post-SDGM (BL-1) Btech(EE 4
th
Yr.)
BHEL, Haridwar IIT ROORKEE





ACKNOWLEDGEMENT

I acknowledge the cordial assistance and guidance provided to
me from several rather unexpected spheres during the course
of this six weeks of study.It would be my pleasure to express
my gratitude to each and every one of them.
I am extremely thankful to Mr. RAJENDRA KUMAR for
providing me with an opportunity to undergo training under
his guidance and imparting me a very deep knowledge of
practice aspect of industrial work culture.

I express my thanks and gratitude to Mr. Satish k Singh and
other authorities of BHEL for instructing me to during whole
training process in this organization and letting me to gain
some work experience.











Table of Contents

1. Introduction
2. Coil & insulation manufacturing shop(block-4)
3. Electrical machine block(Block 1)
4. Manufacturing Process of turbo generator
5. Introduction to 500 MW Turbo Generator
6. Constructional Features of core
7. Constructional feature of stator body
8. Constructional feature of rotor
9. Constructional features of winding
10. Working Principle
11. Cooling System
12. Excitation system
13. Electrical Generator Protection
14. Conclusion








INTRODUCTION

One of the Indias largest manufacturing and engineering enterprise in energy
specific infrastructure today, a 40 odd years ago,leading the way in indigenously
developes Heavy electrical equipment Plant , that has been well recognized as a
great arena of performance .BHEL manufactures a range of up to 30 general
product,over 180 products and feeds to the major sector of the
indian markets, Transportation, Power transmission and generation
industry, Telecom,energy sector. Its wide network has four Power
Sector regional centre,14 manufacturing divisions, 18 regional
offices, eight service centre, over 100 projects sites making the
company enable to sincerely cater its customers providing them
appropriate products, enhanced services and system at reasonable
prices. This higher reliability and quality outcomes are because of
greater emphasis on engineering, design, producing at international
levels with best technologies of world and the technologies of its
own R&D centre.

Feature of BHEL
More than 90000 MW of power generation for all the varied sphere
houses of power consumers.
2,25,000 MVA of transformer capacity and all equipment in
transmission and distribution network of upto 400 KV of AC& DC.
25000 motors been supplied with drive control system to Refineries,
power projects, aluminum, Petrochemical, fertilizers, cement plants
Steel, Fertilizer.
Over 12000 km of railway network been fed in form of Traction electric
and AC&DC locos
Over one million valves to power plants and other industries has been
supplied.


HEEP
HEEP, (Heavy Electrical Equipment Plant) manufactures electrical
devices for the Turbo Generators production.In HEEP there is
production of turbo generator, exciter, turbine, AC/DC motor, etc. HEEP,
started the production from January 1967. Over 40%, electrical energy
generated from the power equipment by BHEL, Haridwar.


COIL & INSULATION MANUFACTURING SHOP (BLOCK-4):-

BAY-1: Bar winding shop, manufactures stator winding of generator.
BAY-2: Manufactures heavy duty generator stator bars with CNC
machine No. 3-464 i.e. Robol bar centre.
BAY-3: Insulation detail shop, Manufactures hard insulation & then
machines insulation of hard part (Glass textolite) such as packing
washers ,wedges, insulation boxes etc.
Bar Shop: Manufacture turbo generators stator winding coil.

Why it is called a bar:-
It is difficult to manufacture, wind in and handle the stator slot for
higher generation capacity generators because of heavy weight and
bigger size.So coil is made in two parts. One part is bottom part of coil
called bottom or lower bar and other part of coil is upper bar or top bar.

TYPES OF GENERATOR:
The generator classified,as based upon the used cooling system in it
such as: TARI, THRI, THDD, THDF, THDI, THW, THFF.
T= First word denotes type of generator i.e. turbo generator or hydro
generator.
A/H= Second word stands for medium used for the cooling of rotor as
air or hydrogen gas.
R/D/I/F= Third word signifies cooling of rotor as radial, forced,indirect,
direct.
D/I/F= Last word signifies type of cooling if stator as indirect cooling,
forced cooling, direct cooling.
W= Medium being used for cooling of stator coil as water

Resin System
Thermo reactive or Rich resin insulation system :
Bond content of resin is 35-37% in this insulation system. The raw
material required preservation and working on temperature 20-25C and
are ready to use. Its shelf life is one year when kept at temperature 20C
which is increased from when at a temperature of 5C.

Micalastic or Poor Resin system :
Bond content in this system of resin is 5-7% and accelerator treatment
is used for preparing insulating material. No requirement of temperature
control. The insulating material, applied on job and then is impregnated
in resin.



MANUFACTURING OF BARS:
Some points in manufacturing process are in brief below-

Conductor Cutting:
This is done by an automatic CNC machine. In this process number of
pieces of pre insulated copper conductor is cut in required length (length
given in drawing as per design).And then insulation is removed out from
both side of copper conductor.




Transposition of conductor:
Transposition refers to changing/shifting position of conductors in
active core (slot) part .The required number of conductors after being
cut,is arranged in the comb in staggered manner and then with help of
bending die, bend are given to the conductors at needed distance.The
conductors are then taken out of the comb & die and are placed with
their end with the line for transposition to be carried out.For making
another half of the bar same is repeated. Then the two halves are
overlapped with a spacer placed in between.
Crossover insulation:
Due to mechanical bending in die the pre insulation may be damaged,
hence at crossover position the spacers are provided. A filler material
(insulating putty of moulding mecanite ),to maintain the rectangular
shape and to cover the difference of levels of conductor , is provided
along height of bars is provided.
Stack Consolidation:
The core of bar is pressed in a press(closed box) under high pressure
(varies from product to product) and a temperature of 160C for a given
period. Dimensions are checked after consolidated stack is withdrawn
from press.
Inter Strand Short Test:
The consolidated bar stack is tested for short between conductors, if
found then it is rectified.
Forming:
The straight bar stack is formed as per overhang profile (as per design).
After forming overhang portion is consolidated.
The straight bar stack is bend at the two end portion as per requirement
design.
Brazing of coil Lugs:
The electrical connection contact in water box for inlet or outlet are
brazed in case of water cooled generator bars. The water box is also
known as contact slew. The contact slew is brazed with the help of
copper aluminium alloy rod. This rod is brought to touch to hot contact
slew and after melting it fill the spaced, in this manner the bar is brazed.
Nitrogen leak test:
For a given duration nitrogen flow test, pressure test and nitrogen leak
test is tested.
Thermal Shock Test:
To ensure thermal expansion and contraction in joints, thermal shock
test is done by 23 cycle of cold and hot water flow. The temperature of
hot water is about 80`C and the cold water is 30`C. By doing this test if
there is any fracture or voids at the joints are present , then it exposed
and easily detected.
Helium leakage test:
This test is performed after the thermal shock test. With the help of this
test we can found very minute leakage if present. In this test the helium
gas pipe is connected at one end and the other end is closed. After this
we insert a helium spectrometer to measure the pressure of the helium
gas.

Baking and Impregnation :
Micalastic system:
For poor resin system,insulated bars for filling of air gaps are dipped in
heated resin.After draining extra resin it is baked under required
pressure and tempreature
Thermo reactive system:
For reach resin system bar is pressed in closed box and baked under
required temperature and pressure.
VPI Micalastic System :
Bar impregnated in resin and fixture with box is baked under required
temperature.


VIP Micalastic system :
Separate bar heated in vacuum and then dipped in resin. After taking
out is pressed in a closed box and baked at given temperature and
pressure.
Insulation:
Number of layer is provided in insulation to increase the thickness of
insulation.
Finishing:
Baked bars are then smoothened and calibrated for dimensions.

Conducting varnish coating:
End corona Protection:
To minimize end corona and prevent discharge, gray semiconducting
varnish applied on core ends.
OCP (Outer Corona Protection) Coating
Black semiconducting varnish is applied.

Testing:
Tan0 Test: This test ensure quality of dielectric material.
H.V. Test: Bars are tested momentarily for high voltages.

Dispatched for winding:
Bars sent to block-1 for winding with preserved in polythene sleves.





ELECTRICAL MACHINE (BLCOK-1):
INTRODUCTION:-
1- Block first is design to manufacture Turbo Generators.
2- The block consist of 4 bays-Bay 1(36*482meters), Bay-2(36*360
meters), and Bay-3 & Bay-4(of size 24*360 meters each).
3- Testing facilities of turbo generator are available in Bay-2
4- There is a special test bed area for testing of T.G. of capacity of
500MW unit sizes.


MANUFACTURING PROCESS OF TURBO GENERATOR:-
Fabricated components are received in respective machine sections from-
Fabrications blocks (block-2,5, 6, 8), while castings and
forgings are received from sister unit CFFP and other indigenous and
foreign sources for turbo generators. Stampings are received from
stampings manufacture block, block-4and coils bars, insulating details
and sheet.
Metal components are received from coils and insulation manufacture
and apparatus and control gear box (Blok-4).


TURBO GENERATOR:-

The turbo-generator is common-shaft excitation AC synchronous
generator with 3phases, 2 poles or with 3 phases, 4 poles.
BHEL,HARIDWAR makes turbo generators that have the brushless
excitation mechanism which has been explained in the NTPC report.
BHEL till today has manufactured Turbo-Generators of up to 560 MW
and is working of going up to 660 MW. It also have capability to take up
the manufacture of TG up to 1000 MW suitable for gas based and
combined cycle power generation and thermal power generation, gas
based also for diverse industrial applications like cement, Paper,
Fertilizers, Sugars Petrochemical, Fertilizers, Rayon Industries, etc.
500MW turbo generator at a glance-
2-pole machine with the following features:-
1- Direct cooling of stator winding with water.
2- Direct hydrogen cooling for rotor.
3- Micalastic insulation system.
4- Spring mounted core housing for effective transmission of
vibration.
5- Brushless excitation system.
6- Vertical hydrogen coolers.
Salient technical data-
1- Rated output :588MVA, 500MW
2- Terminal voltage :21KV
3- Rated stator current: 16KA
4- Rated frequency :50Hz
5- Rated power factor: 0.85 lag
6- Efficiency : 98.55%



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



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

The turbine coupling end
The exciter end

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

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






WORKING PRINCIPLE:-

One end of the alternator is coupled to the turbine and other end is
coupled through the exciter. The whole assembly is on the shaft.
Turbine act as a prime mover, the permanent magnet of the exciter
creates a permanent magnetic field, which is cut by the rotor
conductors. Making the formation of 3-phase power, this 3-phase
power is fed to the thyristor controlled switches for rectification. The
3-phase power is fed to main exciter, after that this 3-phase power
is given to the diode wheel so it is produce the dc power. The dc
power is given to the main alternator field without brushes and slip
ring. Then alternating field is produce by the cut of rotor
conductors making the production of emf by the FARADAYS LAW.



Cooling of the Alternator:-
The machine needs to be cooled to avoid damage and for greater life.
Heating causes insulation failure. Hence, cooling is a very important
factor that needs to be taken care of. For cooling, the stator and rotor are
provided with a ventilation to cool it down. Air gaps are provided
throughout the machine. But for very high power machines
natural cooling is insufficient so a cooling system is provided. For
collection of hot air, a large chamber is provided. This air is cooled and
recycled into the generator. The rotor of the alternator consists of fans
powered by induction motors. They suck in the air and push it through
to the cooling chamber. Another method is also used which is called
hydrogen cooling. Hydrogen acts as ac coolant and the chamber is shut
completely is filled with hydrogen. Hydrogen cools itself. The chamber is
emptied each time the machine is stopped.
TG TEST BED:-
New LSTG [Large Scale Turbo Generator] TEST BED has been put up
with indigenous know how in record time testing Turbo Generator of
rating 500MW and above up to 1000MW. It caters to the most advanced
requirement of testing by employing on line computer for data analysis.



Circuit Breakers:-

By separating two contacts in medium such as SF6, having good
arch quenching and dielectric properties current can be
interrupted. After the contact seperates current flows through an
arc and is interrupted when the arc is cooled by gas blast.Gas blast
should be able to cool it swiftly so the temperature is reduced from
20000K to 2000K in order to withstand transient recovery voltage
after interruption.SF6 normally is used in HV circuit breaker(more
than 52 kV).In this process arc energy is used to generate blast by
thermal expansion and to accelerate circuit breaker on other
hand.Over pressure by arc energy is linked with a pistonwhich
accelerates moving part and increasing energy for tripping.

This interrupting principle with increasing the energy delivery for
tripping maintains the opening speed independent of current.This
mechanism is more favorable in high current circuit breaker.


COOLING SYSTEM:-



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

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




EXCITATION SYSTEM:-

Turbo generator is a doubly excited machine. Because its field
winding is excited by dc source and its armature winding is
connected to ac source. For dc excitation we need use the use of
exciter. Hence there are three types of dc excitation-
1- DC exciter
2- Static excitation
3- Brushless exciter

In BHEL organization brushless exciter is widely use because slip
ring and brushes is absent and it is provide less losses so that its
efficiency is high so we use the brushless exciter. The brushless
exciter is used for generating the dc field which is used to fall on
alternator of rotor. When the dc field is fall on the rotor and the
rotor is directly connected to the turbine so that the turbine is
rotate the rotor, the alternating field is generated by the rotor then
due to the induction the alternating emf is generated in the stator
core. These emf is received by the stator terminal those are called ac
voltage.
The brushless exciter has mainly two parts such has-
1- Pilot exciter
2- Main exciter



In pilot exciter permanent magnet is used, which produce the
permanent magnetic field. Three phase power from pilot exciter is
fed to thyristor controlled bridge to main exciter. After rectification
the controlled dc output is supplied to stationary field winding of
main exciter.




ELECTRICAL GENERATOR PROTECTION:-

Generator may be endangered by short circuit, ground
fault, over voltage, under excitation and excessive thermal
stresses. The following protective equipment is
recommended such as

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







CONCLUSION:-

Bharat Heavy electrical limited being the largest manufacturing and
engineering public sector in india. The sector is an important part
in turbo generators. The stator is assembled by the laminated
sheets. We use the UNIVERSAL FORM FICTURE type bar which
assemble all the straight part and the over hang at a time. The
universal from facture type bar is more flexible and its life time
more. We use the bar transposition for stator winding which is more
advantages. BHEL has acquired the latest technology in the
insulation system, the VACCUM IMPREGINATION system of
insulation, which has various advantages like cost reduction with
improve quality. Thus designed an manufactured start of turbo
generator is used mostly in paper, sugar, cement, petrochemical,
fertilizer, Rayon, industries. The architecture of BHEL, the interlink
of various units and the way working of whole plant is controlled
made me realize that engineering is not just structural description
but greater part is planning and management.
It has allowed us and an opportunity to get exposure to
implementation of theoretical fundamentals.