Training module for Vocational 

Trainees
• BHEL‐An Introduction
• Brief introduction with BHEL units.
• Introduction to BHEL Haridwar.
• Layout of BHEL Haridwar
• Manufacturing blocks of BHEL Haridwar
• Introduction to Turbo Generator's and exciter.
• General principle of TG and exciter.
• Details of major components and assemblies of 
TG.
• Introduction to different assemblies.
• Testing details of TG.
 BHEL‐An Introduction
• It was established in 1964
• HEIL‐Heavy electrical(India) limited was merged with 
BHEL in 1974.
• As of Dec 2015, 63.06% of shares are hold by Indian 
govt.
• Got its Maharatna status in 2013.
• Total installed capacity( Domestic and Overseas) of 
BHEL made equipment's is 135GW
• BHEL holds 57% share of installed capacity, and 65% in 
power generated with thermal sets.
• BHEL has supplied its products to 76 countries.
 Brief introduction with BHEL units
• Centralized Stamping Unit & Fabrication Plant (CSU & FP), Jagdishpur
• Insulator Plant (IP), Jagdishpur
• Electronics Division (EDN), Bangalore
• Industrial Systems Group (ISG), Bangalore
• Electro‐Porcelains Division (EPD), Bangalore
• Heavy Electrical Plant (HEP), Bhopal
• Industrial Valves Plant (IVP), Goindwal
• Heavy Electrical Equipment Plant (HEEP), Ranipur (Haridwar)
• Central Foundry Forge Plant (CFFP), Ranipur (Haridwar)
• Heavy Power Equipment Plant (HPEP), Hyderabad
• Transformer Plant (TP), Jhansi
• Boiler Auxiliaries Plant (BAP), Ranipet
• Component Fabrication Plant (CFP), Rudrapur
• High Pressure Boiler Plant (HPBP), Tiruchirappalli
• Seamless Steel Tube Plant (SSTP), Tiruchirappalli
• Power Plant Piping Unit (PPPU), Thirumayam
• Heavy Plates & Vessels Plant (HPVP), Visakhapatnam
 Introduction to BHEL Haridwar.
• It was developed in 1962 with collaboration of Russia
and Chez technology.
• It has two manufacturing plants, HEEP and CFFP
• Heavy Electricals Equipment Plant is one of the major
manufacturing units of BHEL. The core business of
HEEP includes design and manufacture of large size
steam and gas turbines, turbo generators, heat
exchangers, condensers and auxiliaries.
• Central Foundry Forge Plant (CFFP) is engaged in
manufacture of large size Castings and Forgings of
various types of steels like alloy steels, creep resistant
steel and supercritical grade steel.
Layout of BHEL Haridwar
 Manufacturing blocks of BHEL Haridwar
• BLOCK‐1: manufacturing of turbo generators of all rating, 
assembly and testing of TG up to 1000MW.
• BLOCK‐2: Provides fabricated jobs used for manufacturing 
Turbo generators and turbines.
• BLOCK‐3: Manufactures turbine of all ratings up to 1000MW.
• BLOCK‐4(CIM): manufacture insulation items used in TG and 
TG stator winding bars.
• BLOCK‐4(ACM): Manufactures rotor coils and control gear for 
all ratings. 
• BLOCK‐5: Manufactures fabrication items for EM and turbine 
block.
• BLOCK‐6: Manufactures stampings for turbo generators.
• BLOCK‐7: Supplies wooden boxes for material dispatch.
• BLOCK‐8(HXE): Manufactures heat exchangers and coolers.
Introduction to Turbo Generator's and 
Exciter
• Turbo generator: It is a large electricity generator
driven by prime mover which in case of turbo
generators is a steam turbine.
• Basic Principle: it is based on Faraday's law of
electromagnetic induction, which states that the
magnitude of the EMF induced in a circuit equals
the time rate of change of the magnetic flux
through the circuit, where E is the electromotive
force (EMF) and ΦB is the magnetic flux
How Turbo generators works
• As shown in the above figure, when high pressure steam is
passed through the turbines it expands in the passage
between various stages of blades. The expansion exerts
force on the blades causing the turbine to rotate.
• In power plants all the rotating shafts are coupled with
each other, the rotation of turbine also results in rotation of
generator shaft as well as Exciter shaft.
• The rotation of exciter shaft causes the magnetic field
created by PMG(permanent magnet generator, which is a
16 pole unit) mounted on the exciter shaft to rotate.
• The rotating magnetic filed is cut by the conductors placed
in the pilot exciter(which encapsulates the PMG and
contains field windings) produces 3phase AC current.
• The output 3 phase AC current is converted into variable DC
current with help of AVR(automatic voltage regulator.
• The DC current is fed to the main 3 phase exciter which is
having 6 poles. The current passed through main exciter
creates magnetic field.
• The magnetic field is cut by the conductors placed in the
rotating armature(mounted on the shaft). This create 3
phase AC current in the armature windings.
• The 3 phase AC produced in the armature is rectified in the
diode wheels, which coverts it into DC current.
• The DC current is passed into TG rotor using DC lead
assembly(conductors and contact pins).
• A similar arrangement is there in TG to receive the DC
current from exciter(here it is called as filed lead core bars
and contact pins)
• Below is a figure explaining TG exciter.
Brushless Exciter
• The current carrying rotor is simultaneously rotated along
with turbine shaft produces rotating magnetic field.
• The magnetic filed is cut by the 3 phase stator winding
placed in the stator core, this produces current.
• The current produced in the windings are transferred
through bus bars and drawn a the output of TG using HV
Bushings placed in the terminal box.
Nomenclature of Turbo generators
Example
 Different modules of TG manufactured by BHEL.

Air cooled TARI generators from 75MW to 170MW. 
Cooling circuit of TARI generators
Design features of TARI 
 Hydrogen cooled generators

• THRI type generators, ranges from 120MW to 
350MW.
Cross section view
Ventilation circuit of THRI generators
Design features of THRI 
 Water cooled turbo generators.
• THDF 115/59, 500MW module
Cross section view
Cooling circuit
• THDF 115/67, 600MW module
Cross section of THDF 115/67
Cooling circuit of 115/67 600MW
THFF 125/67 800MW TG
Cooling circuit of THFF 125/67 800MW TG
Technical Specification sheet of all TG
 Major components of Turbo generators
• Stator Frame and cooler housings.
• Stator core
• Bus bars and connecting bus bars
• Stator winding bars
• Wound stator
• End shields
• Shaft seal assemblies
• Rotor shaft
• Rotor coils.
• Wound rotor
• Bearings
 Stator Frame and cooler housings.
• It is a cylindrical structure fabricated using different
plates. The fabrication work is performed in block‐2.
• The core of generator is placed in this stator frame. The
frame withstand the weight of wound core as well as
the various forces produced during operations.
• It has provisions for mounting of end shields and cooler
housing on its end.
• The cooler housing are used as casings for vertical
mounting of hydrogen coolers.
• In THRI generators the hydrogen coolers are mounted
in the stator frame itself.
• In THDF 115/59 type (500MW) TG the end shields TE
have provisions for cooler housings.
Cooler housing(THDF & THFF design) and stator 
frame(THRI design)
End shields Turbine end 115/59 500MW TG.
4 coolers are inserted from top openings.
 Stator core and its major components
• Stator core is made up of thousands of laminated high
silicon sheets/stampings stacked together to form a
cylindrical structure. This form of structure helps in
minimizing eddy current losses.
• The sheets are coated with insulating varnish and have
slots in the inner portion and several holes for
ventilation purpose.
• The main function of core is to carry magnetic flux
generated by the revolving rotor.
• At the end of core there is a stepped arrangement of
sheets is made so as to reduce the eddy current losses
at the end of core.
Example of stamping Stacking of stampings
Cross section of stator core showing stepped 
arrangement of stampings at ends.
Core building of THRI or THDF(600&800MW TG)
 Major components of stator core

• Stampings: these are thin laminated sheets having holes for

cooling(hydrogen passing).
• Core press rings: these are large disc like plate on which core is
build up. These plates are welded with fingers which compresses
the core. The core is build up from exciter side.
• Tension bolts: these are long studs made of steel used to tighten
the core. These are insulated along their length.
• Spring baskets: these are fabricated ring like structure is welded on
the core. When core is inserted into the stator frame the bushes are
welded on the spring as well as on the spring baskets.
• Compression rings: these are also weld in the middle of core.
Generally 6 spring baskets and 2 compressions rings are used in
600MW and 7 baskets re used in 800MW TG.
• Core bars: these are inserted into the core and welded with core
press rings.
 Assembled core along with baskets, 
core press rings and core bars.

Springs welded on stator frame
• Spring THRI • Spring 500MW
• Spring 600MW • 500MW in assembled 
condition
 Core insertion Procedure
• In case of 115/59 or 500MW TG, the core is built in the 
stator body itself, the following steps are involved before 
starting of core building.
1) hydraulic and pneumatic test of stator body.
2) Welding of spring and matching piece with spring baskets.
3) Core bar alignment and welding.
4) Core press ring EE insertion and alignment.
5) Stacking of stampings.
6) 1st , 2nd and 3rd stage heating and pressing
7) Core press ring TE assembly
8) Tension blot insertion and tightening.
9) Core bar alignment and welding.
10) Dove tail bar insertion .
Core pressing
• In case of 115/67 and 125/67 module of generators, the core is
built separately and thereupon it is inserted into the body. The
steps involve in the core building are as follows.
1) Core press ring EE assembly
2) Stacking of core
3) 1st, 2nd and 3rd stage of heating and compression.
4) Assembly of magnetic shunt and end packets.
5) Assembly of core press ring TE.
6) Tension blot insertion and core bar welding.
7) Welding of spring baskets and compression rings on core.
• The hydraulic and pneumatic test of stator body and cooler housing
are done separately. After core insertion the following steps are
involved.
1) Welding of springs with the stator frame
2) Welding of bushes with spring
3) Welding of bushes with spring baskets(mounted on core) after
core insertion and alignment.
Core insertion into stator of THDF type 
TG(600MW and 800MW)
Core insertion of THRI generators
 Wound stator
• Stator winding is done by placing stator on rotating fixture.
After laying of lower and upper bars, these are connected
at the ends.
• The stator has a three phase, double layer, short pitched
and bar type of windings having two parallel paths. Each
slots accommodated two bars.
• Top and bottom bar displaced by one winding pitch and
connected to coil groups(bus bars). Coil groups connected
to Connecting Bus bar and finally to Term Bushings.
• Each bar consists of solid as well as hollow conductor with
cooling water passing through the latter. Alternate
arrangement hollow and solid conductors ensure an
optimum solution for increasing current and to reduce
losses.
• The current flowing through the conductor is uniformly
distributed over the entire bar cross section.
• The manufactured bars are placed in rectangular slots
which are uniformly distributed around the circumference
of the stator core.
• The bars are protected by a cemented graphitized paper
wrapper over the slot portion of the bar.
• Radial locking of the bar is done with slot wedges. A top
ripple spring of high‐strength fiber glass fabric, placed
below the slot wedges, presses the bar with a specific
preloading.
• An equalizing strip is inserted at the slot bottom to
compensate any unevenness in the bar shape & slot
bottom. side gaps are filled with side ripple springs fillers.
Bar laying
 Stator slot of various modules

TARI module THRI module
 Stator slot of various modules

THDF 500MW & 600MW THFF 800MW
 Insulation system of windings

• Bitumen Insulation: also known as thermoplastic

insulation. This system was used in THW type of
generators of rating between 100‐230MW.
• Resin rich insulation: in this type of system,
insulation tape saturated with resin is used for
taping the bars, subsequently these bars are
cured at elevated temperatures during which the
excess resin oozes out. this results in void free
class f insulation.
• Resin rich system: impregnation of bars.
• Limitation of resin rich insulation.
• Resin poor insulation: also known as
micalastic insulation.
• In this system, tape with lesser resin content is
used for taping bars, subsequently vacuum
pressure impregnated in resin tank. The resin
permeate through the insulation from
outside.
• Another type of resin poor insulation is total
impregnation type(VPI), in this system the
complete winding along with the core is
impregnated in resin tank which results in
monolithic stator winding.
Vacuum pressure impregnation(VPI)
 Manufacturing of stator winding bar
• The following steps are involved in manufacturing of stator winding
bars.
1) Conductor cutting: This process is done on automatic CNC
machine. In this process the pre‐insulated copper conductor is cut
into number of pieces of required length. Insulation is removed
from both ends of the copper conductor out.
2) Transposition : Transposition means changing/shifting of position
of each conductor in active core (slot) part. Here the conductors
are arranged on the comb in staggered manner and then bends
are given to the conductors with the help of bending die at
required distance. Then the conductors are taken out from the
comb and die and placed with their ends in a line and
transposition is carried out. This process is repeated for making
another half of the bar which would be mirror image of the first
half. The two halves of the bar are overlapped over each other
and a spacer is placed between the two halves
• Transposition(contd.): The transposition provides
for a mutual neutralization of the voltages
induced in the individual strands due to the slot
cross field and end winding flux leakage.
• This ensures that current flowing through the
conductors is uniformly distributed over the
entire bar cross‐section and minimum circulating
current exist thereby reducing current dependent
losses.
• The stator winding bar is being designed with 540
deg. transposition with 2‐plane bending. this
would eliminate strip to strip brazing
3) Crossover insulation : The pre insulation of the copper 
conductor may get damaged due to mechanical bending 
in die during transposition, hence the insulating spacers 
are provided at the crossover portion of the conductors. 
A filler material is provided along the height of the bar to 
maintain the rectangular shape and to cover the 
difference of level of conductors 
4) Stack Consolidation :The core part of the bar stack is 
pressed in press (closed box) under pressure (varies from 
product to product) and temperature of 1600 C for a 
given period. The consolidated stack is withdrawn from 
the press and the dimensions are checked 
5) Inter Strand Short test: The consolidation bar stack is 
tested for the short between any two conductors in the 
bar, if found then it has to be rectified. 
Stacking of coils Forming of bars
6) Forming : The straight bar stack is formed(bended) as
per overhang profile (as per design). The overhang
portion is consolidated after forming
7) Brazing of coil lugs :For water cooled generator bars,
the electrical connection contact and water box for inlet
and outlet of water are brazed
8) Nitrogen leak test :The bar is tested for water flow
test, nitrogen leak test and pressure test for given
duration.
9) Thermal shock Test :The cycles of hot (800C) and cold
(300C) water are flew through the bar to ensure the
thermal expansion and contraction of the joints .
10) Helium leakage test :After thermal shock test bar is
tested for any leakage with the help of helium gas.
Lugs of winding bar Brazing of lugs
Set up for nitrogen leak test Set up for thermal shock test
11) Impregnation and baking.
a) Thermo reactive System: In case of rich resin insulation the bar is
pressed in closed box in heated condition and baked under pressure
and temperature as per requirement for a given period.
b) Micalastic System : In case of poor resin system the insulated bars are
heated under vacuum and the impregnated (dipped) in heated resin so
that all the air gaps are filled, layer by layer, with resin. Then extra resin
is drained out and bars are heated and baked under pressed condition
in closed box fixture.
c) VPI Micalastic System : The bars already laid in closed fixture and full
fixture is impregnated (dipped) in resin and then fixture with box is
baked under given temperature for given duration.
d) VIP Micalastic System : The individual (Separate) bar is heated in
vacuum and impregnated in resin. Then bar is taken out and pressed in
closed box fixture and then baked at given temperature for given
duration.
12) Insulation : The bar is insulated with the given number of layers to build
the wall thickness of insulation subjected to the generating voltage of the
machine.
13) Conducting varnish coating
(i) OCP (Outer Corona Protection) Coating :‐The black
semiconducting varnish coating is applied on the bar surface on
the core length.
(ii) ECP (End Corona Protection) Coating: The grey
semiconducting varnish is applied at the bend outside core end of
bars in gradient to prevent from discharge and minimize the end
corona.
14. Testing of bars
(a)Tan Δ Test : This test is carried out to ensure the healthiness of
dielectric Insulation i.e. dense or rare and measures the
capacitance loss.
(b) H. V. Test:‐The each bar is tested momentarily at high voltage
increased gradually to three times higher than rated voltage.
15) Finishing : The baked and dimensionally correct bars are
sanded ‐ off to smoothen the edges and the surface is calibrated,
if required, for the dimension
 Rotor shaft and its assembly
• TG Rotor shaft is produced form high strength alloy steel
forging. The dimensions of the rotor i.e. diameter and
length depends upon the rating of TG.
• The straight portion of the shaft is known as barrel. It
provides locations(slots,28 no’s) for rotor coils(bars),
cooling vents etc.
• At both ends of the shaft there are provisions for coupling
with the turbine and exciter.
• The flat place between barrel and coupling ends there is
place for placing journal bearings which supports the load
of rotor shaft.
• In case of THRI type TG shaft has defined locations for
installing rotor blades, and in case of THDF and THFF only
turbine end of shaft is having location for blades mounting.
Fig: 28 no's of slots are machined on shaft, the white portion is for
mounting of rotor blades. The adjacent location is for bearings.
 Components of wound rotor
• Rotor shaft: alloy steel forging, houses windings which are used to
create rotating magnetic field
• Retaining rings: it covers the overhang portion of coils form
centrifugal forces action on them due to rotation of rotor.
• Rotor coils: these are copper conductors which carries current from
exciter and create 3phase magnetic field.
• Compressor hub: it is mounted on rotor shaft and grooves are
machined on it for installing blades on them.
• Rotor blades: these are used to create suction effect so that the
cooling gas(either hydrogen or air) is sucked efficiently into the TG.
• Filed lead core bar : these are copper forging used to transfer
current coming form TG Exciter to the rotor windings.
• Current bolts: the current carried by filed lead core bar is
transferred using current bolts to the coils.
• Wedges: these are made of copper and used to create wedging
effect in the rotor slot, which helps in locking of rotor coils in the
slots.
Rotor blades Rotor wedges
 Steps involved in machining of rotor

• When shaft arrives in shop rough turning is done to remove

surface defects and impurities
• Shaft is turned(machined) to its final diameter as per the
type of TG it has to be used in.
• Slots are cut on the shaft. There are 28 no’s of slot in a TG
rotor.
• Coupling holes on both ends are drilled.
• Axial hole on exciter side for core bar insertion there upon
holes for current bolts are drilled.
• Final turning of rotor journal is done after balancing.
 Rotor coils and its laying
• Rotor coils are made up of high conductivity copper strips. The
rectangular cross section copper conductors have ventilating ducts
on the two sides thus providing a channel for hydrogen flow.
• Two individual conductors placed‐one over the other are bent to
obtain half turns. Further these half turns are brazed in series to
form coil on the rotor.
• The individual turns are insulated from each other by layer of glass
strips on turn of copper and baked under pressure and temperature
to give a monolithic inter turn insulation.
• The coils are insulated from rotor body by U‐shaped glass laminate
module slot through made from glass cloth impregnated with epoxy
varnish. At the bottom of slot D‐shaped liners are put to provide a
plane seating surfaces for conductors and to facilitate easy flow of
gas from one side to another.
• The overhang winding is separated by glass laminated blocks called
liners. The overhang winding are insulated from retaining rings
segments having L‐shape and made of glass cloth impregnated by
epoxy resin.
Slot structure of Rotor.(TARI and THRI on left and THDF on 
right)
End windings of rotor shaft.

• The figure shows the

end windings.
• On this portion of
winding retaining ring is
mounted so as to
protect the coils from
flying.
• The overhang spacers
are placed in the slotted
portions.
 Cooling of rotor
• In direct cooling of rotor winding hydrogen gas is directed to the 
rotor end wedges at the turbine and exciter ends. The rotor winding 
is symmetrical relative to generator centerline and pole axis. 
• Each coil quarter is divided into two cooling zones consists of the 
rotor end winding and the second one of the winding portion 
between the rotor body end and the midpoint of the rotor. 
• Cold gas is directed to each cooling zone through separate openings 
directly before the rotor body end. The hydrogen flows through 
each individual conductor is closed cooling ducts.
• The heat removing capacity is selected such that approximately 
identical temperature is obtained for all conductors. 
• The gas of the first cooling zone is discharged from the coils at the 
pole center into a collecting compartment within the pole area 
below the end winding from the hot gases passes into air gap 
through the pole face slots at the end of the rotor body. 
• The hot gas of the second cooling zone is discharged into the air gap 
at the mid length of the rotor body through radial openings in the 
hollow conductors and wedges. 
 End shields
• The end shields are fabricated job used to hold
bearings, shaft seal assemblies and in case of THDF
115/59 type TG it also houses hydrogen coolers.
• It is mounted on both the ends of stator frame with use
of bolts.
• On the outer portion of end shields it have several pipe
inlets for oils used for bearing and shaft seal.
• Below is an example of 500MW end shields(TE and EE),
as its clear there is no requirement of cooler housing in
500MW type TG.
Turbine end Exciter end
 Bearings
• The main purpose of bearings is to support
the weight of rotor shaft.
• The bearings are babbited to reduce friction
between shaft and bearings.
• Oil is supplied in the lower portion of bearing
which creates thin film of oil between inner
portion of bearing and rotor shaft. This film
helps to reduce friction between layers when
shat is rotating.
 Shaft seal assembly
• These consist of several critical components required
to prevent leakage of hydrogen from stator body.
• Shaft seal is also purged with oil which creates oil film
between seal ring and rotor shaft journal.
• It also has oil catcher and oil wipers which prevents oil
leakage into stator.
• Labyrinth rings are used in the inner portion(hydrogen
side) of stator and are mounted on end shields to
restrict any flow of hydrogen through them.
• Seal rings are babbited on their portions, their main
function is to prevent hydrogen leakage.
 Static excitation system
• In this kind of excitation system, the rotor filed
windings are excited with the current coming from slips
rings mounted at exciter end of rotor shaft.
• The current is transferred to the slip rings using carbon
brushes mounted on brush gear stand. Generally the
external current is supplied to the brush gear through
the cable lugs attached to the brush gear stand.
• The brush gear contains number of carbon brushes
which are in constant touch with the slip rings which
transfers the current to rotor windings via current bolts
and filed lead core bar.
Slip rings Brush gear
Brushless Excitation System
Brushless Excitation contd.
TG Exciter in assembled form
Major assemblies of exciter‐Main Exciter
Rectifier wheel Pilot exciter and PMG
Testing of Turbo generators
Testing of Turbo generators. Contd.
Testing of Turbo generators. Contd.