MANUFACTURIN

G PROCESS
OF
TURBO
GENERATORS

"In the field of observation, chance favors only the

prepared mind."

MANUFACTURING PROCESS OF TURBO

GENERATORS
A Mini Project Work
Submitted in partial fulfillment of the
Requirements for the award of degree of
BACHELOR OF TECHNOLOGY
In

ELECTRICAL & ELECTRONICS

ENGINEERING
By

K.GOPI KRISHNA (07401A0218) B.NAVEEN KUMAR REDDY (07401A0204)

CH.GRACY VIMALA (07401A0212) B.SHRAVANA SWAROOP (07401A0205)
Under the guidance of

Ms. PARVATHI
Assistant Professor

Dept. of Electrical & Electronics Engineering

DVR COLLEGE OF ENGINEERING &
TECHNOLOGY
KASHIPUR (VILL), SANGAREDDY (M), MEDAK (D).

2010
ACKNOWLEDGEMENT
We take this opportunity to record our gratitude to all those who helped us
in successful completion of the project.
We take immense pleasure in thanking Prof. V. LAKSHMIPATHY garu,
Principal of our college and Prof. A. SUNDARAM garu, Head of the department
for having permitted us to carry out this project.
We wish to express our deep sense of gratitude to our Internal Guide Ms.
PARVATHI for her able guidance and useful suggestions, which helped us in
completing the project work in time.
We immensely be grateful to Sri. B. PRASADA RAO garu, CEO (chief
executive officer) of BHARAT HEAVY ELECTRICALS LIMITED for giving
us permission for undergoing study project training in their company.
We wish to thank Smt. B.K. SARALA ANAND garu, HRD-MANAGER, BHEL
for allotting us this project.
We also wish to thank Sri. V.RANGA RAO garu, Dy.Manager, EM (Production),
BHEL for his time to time needed valuable guidance.
Finally, we wish to express our profound thanks to all the employees, in charges
and workmen without whose support, completion of this project would have
been impossible.

ABSTRACT

BHEL is the largest engineering and manufacturing enterprise in India in

the energy related infrastructure sector today which manufactures turbo generators
(2-pole and 4-pole) ranging up to 150 MHz.
The manufacturing process of turbo generator is mainly divided into stator
section and rotor section where stator frame, stator core, stator windings, end
covers are received from the stator building section and rotor with rotor windings
and rotor retaining rings is received from rotor section and assembled at the
assembly section. Each and every process is carried out in a sequential process.
Turbo generators are designed with the Closed circuit air cooling with water or air
coolers mounted in the pit.
The layout of the manufacturing plant is such that it is well streamlined to
enable smooth material flow from the raw material stages to finished goods. The
raw material that are produced for manufacture are used only after thorough
material testing in the testing lab and with strict quality checks at various stages of
productions. Latest technologies like vacuum press impregnated micalastic high
voltage insulation, polyester fleece tape impregnation for outer corona protection
are implemented to produce high quality insulation for turbines, outstanding
performance and long lasting lifetime.

INDEX
Chapter 1

1-2

ABOUT THE COMPANY: BHARAT HEAVY ELECTRICALS LIMITED.

Chapter 2

3-4

2. Introduction
2. History of Turbo Generators
3. Principle of operation
4. Synchronous generators classification based on the medium used for
generation
5. Components of Turbo Generator
1.

Stator

2.

Insulation

3.

Rotor

Chapter 3
3. Stator
1. Stator frame
2. Stator core
3.2.1 The purpose of stator core
3. Preparation of laminations
1.

Compounding operation

2.

Blanking & notching operation

3.4 The different operation in manufacturing of laminations

3.4.1 Deburring operation

5-14

3.4.2 Varnishing
5. Assembly of core
6. Stator windings
1.

Slot discharges

2.

Manufacture of stator coils

3.

Process of taping

7. Stator end covers

1.

Phase connectors

2.

RTDs

Chapter 4

14-15

4. Assemble of windings
1. Winding holder assembly
1.

Assembly of HG rings

2.

Identification of RTD slots

2. Bottom bars Laying

1.

Pressing of bottom bars

2.

Inter layer inserts & RTDs assembler

3.

Stiffner assembler

4.3 Top bars laying

4.3.1 Pressing of top bars
4.4 Connecting rings assembly
Chapter 5
17
5. Insulation system

16-

1. BHEL insulation system for Turbo Generators

2. BITUMEN system & life extension
3. Various insulation system & practices
Chapter 6

18-22

6. VPI system
1. Introduction to VPI system
2. Features and benefits
3. VPI of resin poor insulated jobs
4. Process of VPI
7. General
8. Preheating
9. Impregnation
10.Post curing
11.Electrical testing
Chapter 7
27
7. Rotor
1. Rotor shaft
2. Rotor winding
1.

Construction

2.

Conductor material

3.

Insulation

4.

Rotor slot wedges

7.3 Rotor Retaining rings

23-

7.4 Rotor fans

Chapter 8& 9.

28-29

8.Bearings
9.Ventilation & Cooling
Excitation system
Chapter 10

30-

33 Testing
10.1 Testing of Turbo Generator
1.

Routine tests on Turbo Generator

1.

Short circuit test

2.

Open circuit test

2.

Measure of shaft voltage

3.

Checking of phase sequence

5.

Before HV test

6.

HV test

7.

Measurement of DC resistance of stator & rotor

Chapter 11
Conclusion and Future scope
REFERENCES
35

34

ABOUT THE COMPANY: BHARAT HEAVY ELECTRICALS

LIMITED

CHAPTER 1

ABOUT THE COMPANY: BHARAT HEAVY ELECTRICALS LIMITED

Bharat Heavy Electrical Limited (BHEL) is today the largest engineering
Enterprise of India with an excellent track record of performance.
Its first plant was set up at Bhopal in 1956 under technical collaboration with M/s. AEI,
UK followed by three more major plants at Haridwar, Hyderabad and Tiruchirapalli with
Russian and Czechoslovak assistance.
These plants have been at the core of BHELs efforts to grow and
Diversify and become Indias leading engineering company.
The company now has 14 manufacturing divisions, 8 service centers and 4 power sector
regional centers, besides project sites spread all over India and abroad and also regional
operations divisions in various state capitals in India for providing quick service to
customers.BHEL manufactures over 180 products and meets the needs of core sectors
like power, industry, transmission, transportation (including railways), defense,
telecommunications, oil business, etc.
Products of BHEL make have established an enviable reputation for high quality and
reliability. BHEL has installed equipment for over 62,000 MW of power generation for
Utilities, Captive and Industrial users.
Supplied 2,00,000 MVA transformer capacity and sustained equipment operating in
Transmission & Distribution network up to 400kV AC & DC, Supplied over 25,000
Motors with Drive Control System Power projects.
Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants etc., supplied
Traction electric and AC/DC Locos to power over 12,000 Km Railway network.
Supplied over one million Valves to Power Plants and other Industries.
This is due to the emphasis placed all along on designing, engineering and manufacturing
to international standards by acquiring and assimilating some of the best technologies in
the world from leading companies in USA, Europe and Japan, together with technologies
from its-own R & D centers.
BHEL has acquired ISO 9000 certification for its operations and has also adopted the
concepts of Total Quality Management (TQM).
BHEL presently has manufactured Turbo-Generators of ratings up to 560 MW and is in
the process of going up to 660 MW.
It has also the capability to take up the manufacture of ratings unto 1000 MW suitable for
thermal power generation; gas based and combined cycle power generation as-well-as
for 13 diverse industrial applications like Paper, Sugar, Cement, Petrochemical,
Fertilizers, Rayon Industries, etc.
The Turbo generator is a product of high-class workmanship and quality. Adherence to
stringent quality-checks at each stage has helped BHEL to secure prestigious global
orders in the recent past from Malaysia, Malta, Cyprus, Oman, Iraq, Bangladesh, Sri
Lanka and Saudi Arabia. The successful completion of the various export projects in a
record time is a testimony of BHELs performance.
Bharat Heavy Electrical Limited (BHEL) is, today, a name to reckon with in the
industrial world. It is the largest engineering and manufacturing enterprises of its kind in
India and is one of the leading international companies in the power field.

 BHEL offers over 180 products and provides systems and services to meet the needs of

core sections like: power, transmission, industry, transportation, oil & gas, nonconventional energy sources and telecommunication.
A wide-spread network of 14 manufacturing divisions, 8 service centers and 4 regional
offices besides a large number of project sites spread all over India and abroad, enables
BHEL to be close to its customers and cater to their specialized needs with total
solutions-efficiently and economically.
An ISO 9000 certification has given the company international recognition for its
commitment towards quality.
With an export presence in more than 50 countries BHEL is truly Indias industrial
ambassador to the world.
BHEL Hyderabad units manufacture includes the following.
Gas turbines
Steam turbines
Compressors
Turbo generators
Heat Exchangers

Pumps
Pulverizers

Switch Gears
Oil rigs
BHEL Hyderabad is the only one in Asia that has the latest type of insulation system called the
Vacuum Pressure Impregnation System.

INTRODUCTION

CHAPTER 2

2. INTRODUCTION:
1.TURBO GENERATOR
A turbo generator is a turbine directly connected to electrical generator for the generation of
electric power. An electrical generator is a machine which converts mechanical energy to
electrical energy.

2. HISTORY OF TURBO GENERATORS:

Generators are based on the theory of electromagnetic induction, which was discovered by
Michael Faraday in 1831, a British Scientist. Faraday discovered that if an electric conductor,
like a copper wire, is moved through a magnetic field, electrical current will flow(be induced) in
the conductor. So the mechanical energy of the moving wire is converted into the electric energy
of the current that flows in the wire.

3. PRINCIPLE OF OPERATION:
Turbo generator or A.C. generators or alternators operates on the fundamental
Principles of FARADAYS LAWS OF ELECTROMAGNETIC INDUCTION. In them the
standard construction consists of armature winding mounted on stationary element called stator
and field windings on rotating element called rotor. The stator consists of a cast-iron frame,
which supports the armature core, having slots on its inner periphery for housing the armature
conductors. The rotor is like a flywheel having alternating north and south poles fixed to its outer
rim. The magnetic poles are excited with the help of an exciter mounted on the shaft of alternator
itself. Because the field magnets are rotating the current is supplied through two slip rings. As
magnetic poles are alternately N and S, they induce an e.m.f and hence current in armature
conductors. The frequency of e.m.f depends upon the no.
of N and S poles moving past a conductor in 1 second and whose direction is given by Fleming
s right hand rule.

4.SYNCHRONOUS GENERATORS CLASSIFICATION BASED ON THE

MEDIUM USED FOR GENERATION:
Turbo generators in Thermal, nuclear, Gas station
High speed 3000 rpm
Min poles 2 poles
Horizontal construction
Cylindrical rotor
Hydro generators in hydel plants

low speed 1000 to 500 rpm

more poles 6 or more

vertical construction

salient rotor

5. COMPONENTS OF TURBO GENERATOR:

1.

STATOR
Stator Frame
Stator Core
Stator Windings
End Covers

2.

INSULATION

3.

ROTOR
Rotor Shaft
Rotor Windings
Rotor Retaining Rings

The following auxiliaries are required for operation:

Bearings
Cooling System
Oil Supply System
Excitation System

STATO
R

CHAPTER 3

3. STATOR
3.1 STATOR FRAME:
The stator frame is of welded steel single piece construction. It supports the laminated core and
winding. It has radial and axial ribs having adequate strength and rigidity to minimize core
vibrations and suitably designed to ensure efficient cooling. Guide bars are welded or bolted
inside the stator frame over which the core is assembled. Footings are provided to support the
stator foundation.

Fig: stator frame

3.2 STATOR CORE:The stator core is stacked from the insulated electrical sheet steel lamination and
mounted in supporting rings over the insulated dovetail guide bars. In order to minimize eddy
current losses core is made of thin laminations. Each lamination layer is made of individual
sections. The ventilation ducts are imposed so as to distribute the gas accurately over the core
and in particularly to give adequate support to the teeth.
The main features of core are
1. To provide mechanical support.
2. To carry efficiently electric, magnetic flux.
3. To ensure the perfect link between the core and rotor.

Fig: stator core

1.

THE PURPOSE OF STATOR CORE

To support the stator winding

To carry the electromagnetic flux generated by rotor winding.
So selection of material for building up of core plays a vital role. The losses in the core are of
two types.
Hysterysis Loss: Due to the residual magnetism in the core material.
Hysterysis loss is given by
Wh max 1.6

Eddy Current Loss: Due to the e.m.f induced in the core of the stator. Eddy current loss is
given by
We max2 f2 t2
In order to reduce the hysterysis loss, silicon alloyed steel, which has low hysterysis constant is
used for manufacture of core. The composition of silicon steel is
Steel - 95.8%
Silicon 4.0%
Impurities - 0.2%
From the formula it is seen that eddy current loss depends on the thickness of the laminations.
Hence to reduce the eddy current loss core is made up of thin laminations which are insulated
from each other. The thickness of the laminations is about 0.5mm. The silicon steel sheets are of
COLD ROLLED NON-GRAIN ORIENTED (CRANGO) type as it provides the distribution of
flux throughout the laminated sheet.

3. PREPARATION OF LAMINATIONS:
For high rating machines each laminations is build of 6 sectors (stampings), each of 60 cut
according to the specifications. Press tools are used in the manufacture of laminations. Press
tools are mainly of two types.
Compounding tools.
Blanking and slot notching tools.
LAMINATIONS ARE MANUFACTURED IN TWO DIFFERENT WAYS

1.

COMPOUNDING OPERATION:

In this method the stamping with all the core bolt holes, guiding slots and winding slots is
manufactured in single operation known as Compounding operation and the press tool used is
known as Compounding tool. Compounding tools are used for the machines rated above 40 MW.

2.

BLANKING AND NOTCHING OPERATIONS:

In case of smaller machines the stampings are manufactured in two operations. In the first
operation the core blot holes and guiding slots are only made. This operation is known as
Blanking and the tools used are known as Blanking tools. In the second operation the winding
slots are punched using another tool known as Notching tool and the operation is called
Notching.

4.THE DIFFERENT OPERATIONS IN MANUFACTURE OF

LAMINATIOS:
1.

Deburring operation:

In this operation the burrs in the sheet due to punching are deburred. There are chances of
short circuit within the laminations if the burrs are not removed. The permissible is about 5
micrometer. For deburring punched sheets are passed under rollers to remove the sharp burs of
edges.

2.

Varnishing:

Then depending on the temperature withstand ability of the machine the laminations are
coated by varnish which acts as insulation. The lamination sheets are passed through conveyor,
which has an arrangement to sprinkle the varnish is obtained. The sheets are dried by a series of
heaters at a temperature of around 260-350 C. Two coatings of varnish are provided in the above
manner till 12-18mm thickness of coat is obtained.
The
prepared
are subjected
to following
tests:
Xylol
testlaminations
To measure
the chemical
resistance.
Mandrel test -

When wound around mandrel there should not be any

Minimum 7H pencil hardness.

cracks.
For 20 layers of laminations insulation.
Hardness test
IR value test
3.5 ASSEMBLY
OF CORE:
The stator laminations are assembled as separate cage without stator frame. The entire core
length is made in the form of packets separated by radial ducts to provide ventilating passages for
the uniform cooling of the core. The thickness of each lamination is 0.5mm and the thickness of
lamination separating the packets is about 1mm. The lamination separating each packet has strips
of nonmagnetic material that are welded to provide radial ducts. The segments are staggered
from layer to layer so that a core of high mechanical strength and uniform permeability to
magnetic flux is obtained. Stacking mandrels and bolts are inserted into the windings slot bores
during stacking provide smooth slot walls.

Fig: assembly of core

To obtain the maximum compression and eliminate under setting during operation, the
laminations are hydraulically compressed and heated during the stacking procedure when certain
heights of stacks are reached. The complete stack is kept under pressure and located in frame by
means of clamping bolts and pressure plates.
The clamping bolts running through the core are made of nonmagnetic steel and are
insulated from the core and pressure plates to prevent them from short circuiting the laminations
and allowing the flow of eddy currents. The pressure is transmitted from the clamping plates to
the core by clamping fingers. The clamping fingers extend up to the ends of the teeth thus,
ensuring a firm compression in the area teeth.

Fig: assembled core

The core building or assembling method depends on the insulation system used.
1. For resin rich insulation system the laminations are stacked in the frame itself.
2. For resin poor insulation system (VPI) cage core of open core design is employed.

3.6 STATOR WINDINGS:

Stator winding is the one which induces emf and supplies the load. Stator winding is placed
in the slots of stator core. Due to the advantages of generation and utilization of 3 phase power
we use three phase windings for generation. So number of slots must be a multiple of 3 (or 6 if
two parallel circuits are required).

Generally two layer lap winding, chorded to about 5/6 pitch which practically eliminates 5th
and 7th harmonics from the flux wage or open circuit induced emf wave is used. The stator coil is
made up of number of strips instead of single solid piece to reduce the skin effect.
Copper material is used to make the coils. This is because
i.

Copper has high electrical conductivity with excellent mechanical

properties.
ii.
Immunity from oxidation and corrosion.
iii.
It is highly malleable and ductile metal.
There are two types of coils manufactured in BHEL, Hyderabad.
Diamond pulled multiturn coil (full coiled):
Roebel bar (half coiled).
Generally diamond pulled multiturn coils are used for low capacity machine. In this coils are
pulled in a particular shape similar as diamond thats why they are called so.
In large capacity machines we use ROEBEL bars. These coils were constructed after
considering the skin effect losses. In the straight slot portion, the conductors or strips are
transposed by 360 degrees. The transposition is done to ensure that all the strips occupy equal
length under similar conditions of the flux. High purity (99%) copper conductors/strips are
used to make the coils. This results in high strength properties at higher temperatures so that
deformations due to the thermal stresses are eliminated. The high voltage insulation is provided
according to the resin poor mica base of thermosetting epoxy system. Several half overlapped
continuous layers of resin poor mica tape are applied over the bars. The thickness of the tape
depends on the machine voltage.

Fig: stator windings

1.

Slot Discharges:

Slot discharges occur if there are gaps within the slot between the surface of the insulation and
that of the core. This may cause ionization of he air in the gap, due to breakdown of the air at the
instances of voltage distribution between the copper conductor and the iron.
Within the slots, the outer surface of the conductor insulation is at earth potential, in the
overhanging it will approach more nearly to the potential of the enclosed copper. Surface
discharge will take place if the potential gradient at the transition from slot to overhang is
excessive, and it is usually necessary to introduce voltage grading by means of a semiconducting (graphite) surface layer, extending a short distance outward from the slot ends.

2.

MANUFACTURE OF STATOR COILS:

Various operations carried out during manufacture of stator coil are

1. Set the straightening and cutting machine using guide pilot.

2. Cut the conductor strips as per the requirement.

3. Set the press for Roebel Transposition.

4. Assemble strips with respect to template and transpose.

5.Assemble both halves of coil sides to from

1.One Roebel half bar

2. Insert insulation of halves between quarter bars matching the straight part zone as
per drawing.

Fig: stator coils

6.Cure half coil on hydraulic press. This process is known as Baking.

(a) Remove insulation at the ends of the strips.

 (b) Test for inter-strip and inter-halves shorts.

7.Set the universal former as per standards. Check the setting of universal former for
(a)Length of straight part also mark diagonals/former walls inside for cross check.
(b)Check for marking made by template.
8.(a) Place the bar on former.
(b) Form the overhang bends as per standards.
Remove clamps and inserts overhand insulation to both roebel halves with an
application of araldite mixture.
(d) The bar is allowed to cure by giving supply to heating clamps.
9.Remove heating clamps and take out the bar halves from former.
(b)Round off sharp edges of straight part and dress up overhang halves insulation of both
halves with out damage to copper strip insulation and to copper stacks.

3.6.3 PROCESS OF TAPING:

1.Tape the bar with Resin poor fine mica paper tape on straight part of bar taking copper foil
outside the tape.
2.Tape with one layer of conductive polyester fleece tape.
a)Provide main insulation
b)OCP protection tape
3.Tape the straight part of bar with conductive polyester fleece tape with starting and ending
shall be on straight part of bar.
4.Tape with mica splitting tape with accelerator taking Ocp layer into and leaving.
5.Tape the straight part of bar with polyester Conductive fleece tape.
6.Provide End Corona protection taping.
7.Provide overhang with protective tape (Polyester glass tape)
8.Test for inter-strip shorts.

Fig: mica taping machine.

7. STATOR END COVERS:

The stator end covers are attached to end flanges of stator frame and also rest on the foundation
plate. The end covers are made up of non-magnetic material (Aluminium castings) to reduce
stray load and eddy current losses.

1.

PHASE CONNECTORS:

The phase connectors consist of flat copper sections, which results in low specific current
loading. The phase connectors are wrapped with resin rich mica tape. After curing the
connectors are attached to the pressure plate with clamps and bolts.

2.

RESISTANCE TEMPERATURE DETECTORS :

The temperature measurements on the generator are made with RTDs. They are placed at various
sections of the core and winding. When making measurements with RTDs the resistance element
is exposed to the temperature to be measured.
The RTD works on the principle of the change in electrical resistance of a conductor due to
temperature. R= Ro (1+ T) ;Where Ro = reference resistance at room temperature; R=
temperature coefficient of resistance ; T = temperature difference in C.

ASSEMBLE OF WINDINGS

CHAPTER 4

4.1 WINDING HOLDER ASSEMBLY:

Assemble the winding holder as per the drawing requirement and check all the winding hold
with template with respect to core.

1.

ASSEMBLY OF HG RINGS:

Assemble the HG rings on the both the side, turbine side as well as laminated side. Pass HGL
gauge in all the slots to detect laminations projection of the bottom surface if any lamination
projection are noticed then rectify the projection. Check prior operation completion.

2.

IDENTIFICATION OF RTD SLOTS:

Identify all the RTD slots with respect to the drawing and assemble the RTD slots as per the
drawing purposes required. Identify all the slots with slots number as per the drawing.

2. BOTTOM BARS LAYING:

1.Pressing of bottom bars:
Each individual bars subjected for pressing at 60 kg/cm2 horizontal & vertical in order to

obtain predetermine the dimensions up to 30 minutes.

This process is carried out for all the bottom bars before laying to the respective slots.
By following above procedure first bar is layed in to the respective slots when the bar is
center to the core centre by measuring pitch dimensions on both sides.
Similarly next bar is layed in to the respective bar by following procedure.
After laying the every two bars the over hangs are reinforced with glass mat at three
different locations on both sides and tying the bars with neoprene glass view.
Similarly the above procedure is following for all the eliminating bars.
After completion bottom bars laying the bars reinforced end wedges and middle
wedges.
Then the bottom bars are subjected to D.C high voltage.

2.Inter layer inserts & RTDS assembles: All the inter layer inserts & RTDS are
assembled as per drawing required i.e. inter layer inserts are assembled in each and every slots
except RTDS slots. In RTDS slots only RTDS are assembled before laying top bars.

3.

Stiffner assembles:

Stiffner are assembled on the winding layers on to the bottom bars by reinforcing & placing glass
mat and tieing with neipring glass. Stiffeners are carried out on the both sides.

4.3 TOP BARS LAYING:

1.

Pressing of top bars:

Each individual top bar is subjected to pressure 60kg/cm2 horizontally and vertically for

duration of 30minutes in order to obtain pre determine dimensions.

The above operation for each top bar before laying in to their respective slots.
First top bar laying is carried out by centering the bar with respect to the stator core &

check the pitch dimensions on both sides.

Similarly the next bar is assembled in to respective slots by following the above
procedure.
After laying every two bars the over hangs are reinforced by inserting glass mat at 3
different locations on the both sides.
By following the above procedure all the top bars are layed in to the slots by full filling
the drawing requirements then the top bars are reinforced wedging with HGW over layer
and placing glass mat under the wedges.
All the respective wedges are driven by matching with respective ventilation holes of the
pores.
Similarly all the wedges are driven in all respective slots by blocking the top bars.
After completion top bars laying top bars are subjected to D.C. high voltage.

4.4 Connecting rings assembly:

All connecting rings assemble as per the drawing requirements, and then the phase
groups are processed by jointing, bracing and insulation. After completion of jointing bracing
and insulation once again it is subjected to D.C. high voltage. Termination of desired RTDS
on one side for monitoring the post curing temperature.

INSULATION
SYSTEMS

CHAPTER 5

5.1BHEL INSULATION SYSTEM FOR TURBO GENERATORS:

BHEL had Bitumen insulation system for low & medium rating TGS and switched over to resin
rich Thermo setting type as a step towards increasing reliability and upgrading technology.
Micalastic system has been adopted for high rating machinery.

2. BITUMEN SYSTEM & LIFE EXTENSION:

The experience with Bitumen system has been generally satisfactory & practically
negligible service failure has been reported on these sets.
Mechanical damage most commonly associated with this system ie., tape separation, due
to thermal expansion of the winding during normal or abnormal temperature eyeing is not
met any of sets.
Though outage due to insulation failures has been considerably low, yet these machinery
would need to be attended to have life extension above their estimated life of 25 years.
Major inspection of the machine condition is by checking the healthiness of windings &
life of bar insulation.
Rehabilitation, if needed, requires restoration of varnish, removal of bitumen & cleaning,
tightening of fasteners/supports, modification of busbars, use of new wedges & other
winding components.

The replacements are required because of vibration / external damage etc.

5.3 VARIOUS INSULATION SYSTEMS & PRACTICES:

Large & medium range motors are provided with following insulation system.
1.Resin flux Insulation System : This system is used on earlier designs & where duplicate or
spare motors to suit the customer requirements are required. In the coming years this system may
become absolute.
2.Resin Rich micalastic Insulation System : The system provides use of Resin rich polyester
backed epoxy micafolium on straight portion & resin rich polyester backed epoxy mica paper
tape on overhang with a final layer of polyester shrink tape. The system is highly productive
during coil manufacture and housing.
3.Resin poor Micalastic Insulation System: Resin poor micalastic system is adopted for large
range Ac Induction and synchronous machines. Theses are designated to meet specific customer
requirement hence for unique in nature to each other. The main insulation consists of resin poor
epoxy mica paper tape all over the oil periphery with varying number of layers on straight and
overhang portions.
The brief comparison of Resin poor over Resin rich is as follows:

RESIN POOR

RESIN RICH

1.Epoxy resin content is about 8%.

1.Epoxy resin content is about 40%.

2.This method follows Thermo Setting

Process.

2.This method also follows Thermo Setting

Process.

3.There is a need for addition of resin from

outside.

3.Further addition of resin is not required from

outside.

4.Time required for this cycle is less.

4.Its a very long process and time consuming.

5.Repairing is very difficult.

5.Repairing is easy.
6.Over all cost is more.

6.Over all cost is less compared to

resin rich.

VACUUM PRESSURE
IMPREGNATION

CHAPTER 6

1. INTRODUCTION TO VPI SYSTEM:

DR. MEYER brought the VPI system with the collaboration of WESTING HOUSE in the year
1956. Vacuum Pressure Impregnation has been used for many years as a basic process for
thorough filling of all interstices in insulated components, especially high voltage stator coils and
bars.
VPI is a process, which is a step above the conventional vacuum system. VPI includes
pressure in addition to vacuum, thus assuring good penetration of the varnish in the coil.
The result is improved mechanical strength and electrical properties. With the improved
penetration, a void free coil is achieved as well as giving greater mechanical strength.
With the superior varnish distribution, the temperature gradient is also reduced .
In order to minimise the overall cost of the machine & to reduce the time cycle of the
insulation system vacuum pressure Impregnated System is used.
The stator coils are taped with porous resin poor mica tapes before inserting in the slots of
cage stator, subsequently wounded stator is subjected to VPI process, in which first the
stator is vacuum dried and then impregnated in
resin bath under pressure of
Nitrogen
gas.

Fig: VPI system

6.2 Features and Benefits:

State-of-the-art process for completely penetrating air pockets in winding insulation.

 Increases voltage breakdown level. (Even under water!)

Proven submergence duty system
Improved heat transfer- windings are cooler, efficiency is improved.
Improves resistance to moisture and chemicals.
Increases mechanical resistance to winding surges.

6.3 Vacuum Pressure Impregnation of resin poor insulated jobs:

Preheating
Vacuum to
be

Variant-01 Variant-02

Variant-03

60 5 C for 605C for

3hrs
12hrs
0.4mbar
0.2mbar/0.4mbar

603C for 12hrs

maintained

<0.2mbar
(both together shall not
exceed 50hrs including
rising time)

Vacuum

0.2mbar for 9hrs

Stopping vacuum pumps

heating time 3hrs

0.4mbar for 17hrs

for 10min shall check 17hrs

vacuum drop. The vacuum
drop shall not exceed by
0.06mbar for 10min

Increase in 40min
pressure
Maximum 3bar
6.4
pressure
PROCESS:
3hrs
Pressure
holding
1.General:
Post
curing At1405C
for 14hrs

80min

80min

4bar

4bar

3hrs

3hrs

At1405C for
32hrs

At1405C for 32hrs

Any other
information

The jobs that are entering tank for Vacuum Pressurised Impregnation shall not have any
oil based coatings. Any such, rust preventive/ corrosion preventive viz., red oxide etc.,
shall be eliminated into the tank.

Resin in the storage tank shall be stored at 10 to 12C and measured for its
viscosity, viscosity rise.

Proper functioning of the impregnation plant and curing oven are to be checked
by production and cleared for taking up of job for impregnation

2.Preheating:
The job is to be loaded in the curing oven and heated. The temperature is to be
monitored by the RTD elements placed on the job and the readings are logged by
production. The time of entry into the oven, time of taking out and the temperature
maintained are to be noted. Depending on convenience of production the jobs can be
preheated in impregnation tank by placing them in tubs.

The impregnation tubs used for impregnation of jobs are to be heated in the
impregnated tank itself, when the jobs are preheated in the curing oven.

3.

Impregnation:

Job insertion into preheated tub and insertion into tank

By the time, the preheating of job is completed, it is to be planned in such a way that the
heating of tub and tank heating matches with the job. This is applicable when the job is heated in
the curing oven separately. The preheated job is to be transferred into the tub by crane handling
the job safely and carefully with out damage to the green hot insulation.

Insertion of tub with job into the impregnation tank

Fig: VPI Resin tub

The warm tub with job is inserted into impregnation tank by sliding on railing, in case of
horizontal tank. The thermometer elements are to be placed at different places on the job. The
connection for inlet resin is to be made for collection of resin into tub. After ensuring all these
the lid of the impregnation tank is closed. In case of vertical tank the job along with tub is
slinged and inserted carefully into impregnation tank without damage to insulation.

Drying the job in vacuum

The job is to be dried under vacuum. Drain out the condensed moisture/ water at the
exhausts of vacuum pumps for efficient and fast vacuum creation. Also check for oil replacement
at pumps in case of delay in achieving desired vacuum.

Heating the resin in the storage tank The completion of operations of

drying and the heating of the resin in the storage tank are to be synchronized. The
heating of resin in the tank and pipeline is to be maintained as at preheating
temperature.

Admission of resin into impregnation tank

The resin is allowed into the impregnation tank tub if required from various storage
tanks one after the other up to a level of 100mm above the job generally, after which the resin
admission is stopped. After 10mins of resin settling the tank is to be pressurized by nitrogen.
While admitting resin from storage tanks pressurize to minimum so that nitrogen
will not affect resin to spill over in tank.

Pressurizing/gelling

The pressure cycle is to be maintained.

Withdrawal of resin from impregnation tank to storage tank

The resin that is pressurized as per pressure cycle by which the opening of relevant valves
will allow the resin to come back to the storage tank. The job also shall be allowed for dripping
of residue of resin for about 10min. After dripping, withdrawal of resin in various storage tanks
is to be carried out.

Taking out the tub with job from impregnation tank

The lid is then opened after taking precautions of wearing mask and gloves for the
operating personnel as a protection from fumes. The job is withdrawn from
impregnation tank by sliding on railing for horizontal and slinging on to crane for
vertical impregnation tanks.

4. Post curing:

The job is post heated. The time for raising from job temperature to this
temperature as per relevant annexure. The time at which the heating is started, achieved and
maintained is to be logged.

5.Electrical testing:
All jobs that are impregnated till above process, are to be tested for electrical tests. After
ensuring that all the temperature/vacuum conditions stipulated for drying, impregnation and
curing operations have been properly followed, the job is to be released for this operation.

ROTO
R

CHAPTER 7

7. ROTOR:

Rotor is the rotating part of alternator. It is used to support field winding placed in slots on the
rotor.
FOR 2-POLE GENERATOR:
Solid rotors are manufactured from forged alloy steel with suitable alloying elements to achieve
very high mechanical and superior magnetic properties. This type of rotor can withstand even
upto speed of 3000 rpm. Rectangular or trapezoidal rotor slots are accurately machined to close
tolerances on slot milling machine.For indirectly cooled generator rotors, ventilation slots are
machined in the teeth.
FOR 4-POLE GENERATOR:
For directly cooled rotors, sub slots are provided for cooling Generator rotors of 1500 RPM are
of round laminated construction. In this case rotor is made up of two parts (1) core, (2)
lamination. The outer diameter of core and the inner diameter of laminations are equal. So for
inserting the core inside the laminations the laminations are first red heated at medium
temperature for 15 hours in BELL FURNACE. After that the core is shrunk fitted inside the
laminations. Thus punched and varnished laminations of high tensile steel are mounted over
machined shaft and are firmly clamped by end clamping plates.

Fig: rotor body.

7.1ROTOR SHAFT :

Rotor shaft is a single piece solid forming manufactured from a vacuum casting. It is forged from
a vacuum cast steel ingot. Slots for insertion or the field winding are milled into rotor body. The
longitudinal slots are distributed over the circumference such that two solid poles are obtained.
To ensure that only a high quality product is obtained, strength tests, material analysis and
ultrasonic tests are performed during the manufacture of rotor. The high mechanical stresses
resulting from the centrifugal forces and short circuit torques call for a high quality heat treated
steel. After completion, the rotor is balanced in various planes at different speeds and then
subjected to an over speed test at 120% of the rated speed for two minutes.

Fig. rotor shaft.

Approximately 60% of rotor body circumference has longitudinal slots which hold the field
winding. Slot pitch is selected so that the two solid poles are displaced by 180 degrees. The rotor
wedges act as damper winding within the range of winding slots. The rotor teeth at the ends of
rotor body are provided with axial and radial holes enabling the cooling air to be discharged into
the air gap after intensive cooling of end windings.

7.2 ROTOR WINDINGS :The rotor windings consist of several coils inserted into the slots
and series connected such that two coil groups form one pole. Each coil consists of several series
connected turns, each of which consists of two half turns connected by brazing in the end
section. Thickness of each strip can be made upto 10.5 mm but here in BHEL we make only upto
5.3 mm. The rotor bearing is made of silver bearing copper ensuring an increased thermal
stability. For ventilation purpose the slots are provided on the coil and on inter strip insulation
layer both.
The individual turns of coils are insulated against each other by interlayer insulation. L-shaped
strips of laminated epoxy glass fiber fabric with nomex filter are used for slot insulation.

Fig: rotor winding.

The slot wedges are made of high electrical conductivity material and thus act as damper
windings. At their ends the slot wedges are short circuited through the rotor body. The inter
space between the overhang is called slot through.

7.2.1CONSTRUCTION
The field winding consists of several series connected coils inserted into the longitudinal slots of
rotor body. The coils are wound so that two poles are obtained. The solid conductors have a
rectangular cross section and are provided with axial slots for radial discharge or cooling air. All
conductors have identical copper and cooling duct cross section. The individual bars are bent to
obtain half turns. After insertion into the rotor slots, these turns are brazed to obtain full turns.
The series connected turns of one slot constitute one coil. The individual coils of rotor are
connected in a way that north and south poles are obtained.

7.2.2 CONDUCTOR MATERIAL: The conductors are made of copper with a silver
content of approximately 0.1%. As compared to electrolytic copper, silver alloyed copper
features high strength properties at high temperatures so that coil deformations due to thermal
stresses are eliminated.

7.2.3INSULATION
The insulation between the individual turns is made of layer of glass fiber laminate.
The coils are insulated from the rotor body with L-shaped strips of glass fiber laminate with
nomex interlines.
To obtain the required leakage paths between the coil and the rotor body thick top strips of glass
fiber laminate are inserted below top wedges. The top strips are provided with axial slots of the
same cross section and spacing as used on the rotor winding. Insulation b/w overhang is done by
blocks made of HGL.

7.2.4 ROTOR SLOT WEDGES

To protect the winding against the effects of centrifugal forces, the winding is secured in the
slots with wedges. The slot wedges are made of copper alloy featuring high strength and good
electrical conductivity. They are also used as damper winding bars. The slot wedges extend
beyond the shrink seats of retaining rings. The wedge and retaining rings act on the damper
winding in the event of abnormal operations. The rings act as short circuit rings in the damper
windings.

7.2.5 END WINDING BRACING

The spaces between the individual coils in the end winding are filled with insulated members
that prevent coil movement. Two insulation plates held by HGL high glass laminate plates
separate the different cooling zones in the overhangs on either sides.

7.3 ROTOR RETAINING RINGS

The centrifugal forces of the rotor end winding are contained by single piece rotor retaining
rings. Retaining rings are made of non-magnetic high strength steel in order to reduce stray
losses. Each retaining ring with its shrink fitted. Insert ring is shrunk on to the rotor body in an
overhang position. The retaining ring is secured in the axial position by snap rings.

Fig: rotor retaining rings

The rotor retaining rings withstand the centrifugal forces due to end windings. One end of each
ring is shrunk fitted on the rotor body while the other end overhangs the end windings without
contact on the rotor shaft. This ensures an unobstructed shaft deflection at the end winding.
7.4

ROTOR FANS

The cooling air in generator is circulated by two axial flow fans located on the rotor shaft one at
each end. To augment the cooling of the rotor winding, the pressure established by the fan works
in conjunction with the air expelled from the discharge parts along the rotor. The blades of the
fan have threaded roots for being screwed into the rotor shaft. The blades are drop forged from
an aluminium alloy. Threaded root fastenings permit angle to be changed. Each blade is secured
at its root with a threaded pin.

Fig: rotor fan

BEARINGS
VENTILATION AND
COOLING

EXCITER
SYATEM

CHAPTERS 8 & 9

8.BEARINGS
The turbo generators are provided with pressure lubricated self-aligning elliptical type bearings
to ensure higher mechanical stability and reduced vibration in operation. The bearings are

provided with suitable temperature element devices to monitor bearing metal temperature in
operation. From inside the bearings are made of very soft metal called Babbitt so that rotor
doesnt get harmed even if it comes in contact with Babbitt. Inside this Babbitt there is a very
thin film of pressurized lubrication oil on which the shaft rotates.
The temperature of each bearing is monitored with two RTDs (Resistance Thermo Detectors)
embedded in the lower bearing sleeve such that the measuring point is located directly below the
babitt. To prevent damage to the journals due to shaft currents, bearings and oil piping on either
side of the non-drive end bearings are insulated from the foundation frame. For facilitating and
monitoring the healthiness of bearing insulation, split insulation is provided.

9.VENTILATION AND COOLING

Turbo generators are designed with the following ventilation systems:
Closed circuit air cooling with water or air coolers mounted in the pit.
Closed circuit hydrogen cooling with water or hydrogen coolers mounted axially on the
stator frame.
The fan design usually consists of two axial fans on either made of cast aluminum with
integral fan blades or forged and machined aluminum alloy blades screwed to the rotor.
In case of 1500 RPM generators, fabricated radial fans are provided

EXICTATION SYSTEM:

Fig: exciter rotor.

The basic use of given exciter system is to produce necessary DC for turbo generator system.
Principal behind this is that PMG is mounted on the common shaft which generates electricity
and that is fed to yoke of main exciter. This exciter generates electricity and this is of AC in
nature. This AC is that converted into DC and is that fed to turbo generator via C/C bolt. For
rectifying purpose we have RC block and diode circuit. The most beautiful feature is of this type
of exciter is that is automatically divides the magnitude of current to be circulated in rotor
circuit. This happens with the help of AVR regulator which means automatic voltage regulator.
A feedback path is given to this system which compares theoretical value to predetermine and
than it sends the current to rotor as per requirement.

Fig: BLE exciter

The brushless exciter mainly consists of:1.Rectifier wheels

2.Three phase main exciter
3.Three phase pilot exciter
4. Metering and
supervisory equipment.
The brushes exciter is an
AC exciter with rotating
armature and stationery
field.
The armature is connected to rotating rectifier bridges for rectifying AC voltage induced to
armature to DC voltage. The pilot exciter is a PMG (permanent magnet generator). The PMG is
also an AC machine with stationery armature and rotating field. When the generator rotates at the
rated speed, the PMG generates 220 V at 50 hertz to provide power supply to automatic voltage
regulator.

TESTING

CHAPTER 10

10. TESTING OF TURBO GENERATOR:

To ensure that all functional requirements are fulfilled, and to estimate the performance of
generator, the TURBO GENERATORS are required to undergo some tests. For testing, the
TURBO GENERATOR was mechanically coupled to a drive motor-motor generator set with
gearbox. The rotor was excited by thyristor converter system located in an independent test room
and the operation was controlled from the test gallery. The following first two tests will be
conducted on the stator and rotor before assembling and the third and final routine tests will be
conducted after assembling the turbo generator.

10.1 ROUTINE TETSTS ON TURBO GENERATOR

MECHANICAL RUN AND MEASUREMENT OF VIBRATIONS AT RATED
SPEED:
The machine is rolled and run at rated speed after ensuring the bearing oil and kept at rated
speed for stabilization of bearing temperatures.
The vibrations are measured at rated speed on both the bearing housings in Horizontal,
Vertical and Axial directions.
The temperature of stator is monitored by monitoring RTDs embedded in core, tooth and
winding. The vibrations should be less than 5 microns and noise level should be in between 7590 db.

10.1.1 SHORT CIRCUIT TEST :

The machine is prepared for short circuit characteristic using current transformers and
shorting the terminals . The machine is run at rated speed and drive motor input voltage and
current are noted and machine is excited gradually in steps, at 20%, 40%,60%,80%,100% rated
current of machine (In).
The excitation is reduced and cut off. The speed is reduced and the machine is cooled at
lower speed. The temperature are checked from machine RTDs. The machine is stopped when it
is sufficiently cooled down. The stator winding temperature should be less than 60 C) From
the Short Circuit test, we will get copper losses.

The short circuit characteristics is plotted from SCC results by selecting X-axis as field
current and Y-axis as % rated current.

10.1.2 OPEN CIRCUIT TEST :

The machine is prepared for Open Circuit Characteristics.
The machine is run at rated speed and the motor input voltage and current are noted and
machine is excited gradually in steps, cat 20%,40%,60%,80%,90%,95%,100%,105%,110% and
120% of rated voltage of machine (En).
At 100% rated voltage the following parameters are noted:
Shaft voltage, checking of phase sequence, bearing vibration, RTDs readings
The excitation is reduced, cut off, the speed is reduced, and the machine is cooled at lower
speed. The temperatures are checked from machine RTDs. The machine is stopped when it is
sufficiently cooled down. The stator core temperatures to be less than 60 C.
From the Open Circuit test, we will get Iron losses.
The Open Circuit Characteristics is plotted on a graph paper from OCC results by selecting
X-axis as field current and Y-axis as % rated voltage.

10.2 MEASUREMENT OF SHAFT VOLTAGE :

When the rotor shaft rotates inside the stator there will be some induced EMF will be
developed inside the rotor. In addition, this voltage will go to the bearings and pedestal and to the
earth as it is grounded and it will again come back to the pedestal, to the bearings through the
earth. It will become a cyclic process. This voltage has to be reduced otherwise, the rotor will get
heated. For this bearing pedestal is placed on, insulation called HGL.

3.

CHECKING OF PHASE SEQUENCE :

When the machine is under OCC condition at 100% rated voltage, phase sequence of
generator is checked using a phase sequence indicator across PT.

4.

MEASUREMENT OF ROTOR IMPEDANCE (rotor inside stator) :

A variable 50 HZ A.C voltage of single phase is applied across the input leads and readings
of voltage and current are noted down from 50v-200 v in steps of 50V.
Impedance is measured by using the formula:

Z = V/I
Where Z = impedance in ohms; V = voltage in volts; I = current in amps;
Rotor Impedance is measured at standstill and at rated speed of the machine.

5.MEASUREMENT OF INSULATION RESISTANCE OF STATOR AND

ROTOR WINDINGS BEFORE AND AFTER HIGH VOLTAGE TEST
(Machine at rest):
Insulation Resistance of the stator and rotor windings is measured separately before and after
high voltage test using Megger of 2500 V for stator & 1000 V for rotor windings. The Insulation
Resistance values are taken at 15 sec and at 60 sec. The ratio of insulation resistance at 15 sec
and 60 sec is known as Absorption Coefficient. Absorption Coefficient = IR at 60/IR at
15 .This Absorption Coefficient for High Voltage test should be > =1.3

6.HIGH VOLTAGE TEST ON STATOR AND ROTOR WINDINGS

(MACHINE AT REST):
The High Voltage is applied to windings by increasing gradually to required value and
maintained for one minute and reduced gradually to minimum. The transformer is switched off
and winding is discharged to earth by shorting the terminal to earth using earthing rod connected
to earthen wire. The test is conducted on all the phases and rotor winding separately. When High
Voltage test is done on one phase winding, all other phase windings, rotor winding,
instrumentation cables and stator body is earthed.
High Voltage test levels : Stator winding = (2 Ut +1) KV
Rotor winding = (10 * Up) V
Where Ut = Rated voltage of the machine under test
Up = Excitation voltage

10.7 MEASUREMENT OF D.C.RESISTANCE OF STATOR AND ROTOR

WINDINGS IN COLD CONDITION:
In cold condition means that measuring the D.C. resistance of the stator and rotor windings
before testing. Variation of D.C is 5% acceptable. D.C. Resistances of stator and rotor windings
are measured separately using micro ohmmeter. The instrument terminals are connected to the
machine terminals and proper range in the meter is selected.

EVALUATION OF SHORT CIRCUIT RATIO:

From the test data Short Circuit Ratio is calculated using the formula.
S.C.R= Field current at 100% Rated voltage from OCC/Field current at 100% rated current from
SCC.

CONCLUSIO
N AND
FUTURE
SCOPE

CHAPTER 11

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

FUTURE SCOPE:
The technology research and investigations division of BHEL is currently
investigating the technical and logistical merit of performing offline quadratic-rate partial
discharge tests on the stator winding insulation of its hydro & turbo generators. A series of
laboratory based insulation research studies on stator bars have been conducted to gain a better
understanding of the various partial discharge phenomena involved. Results thus far obtained
from these tests have provided valuable insight into the discharge activity of operation.

REFERENCES:
www.indiama
rt.com
www.eriks.co.uk
www.seimens.com
www.bhel.com
A text book of electrical technology by B.L.THERAJA.
A text book of electrical machines by P.S.BIMBRA.

BHEL Internal material.