ABSTRACT

Bharat Heavy Electricals Limited (BHEL) is an Indian integrated power plant

equipment manufacturer and operates as engineering and manufacturing company

based in New Delhi, India. Established in 1964, BHEL ushered in the indigenous Heavy

Electrical Equipment industry in India. The company has been earning profits

continuously since 1971-72 and paying dividends since 1976-78.

It is engaged in the design, engineering, manufacture, construction, testing,

commissioning and servicing of a wide range of products and services for the core

sectors of the economy, viz. Power, Transmission, Industry, Transportation, Renewable

Energy, Oil & Gas and Defence.

It is the 7th largest power equipment manufacturer in the world. In the year 2011,

it was ranked ninth most innovative company in the world by US business magazine

Forbes. BHEL is the only Indian Engineering company on the list, which contains

online retail firm Amazon at the second position with Apple and Google at fifth and

seventh positions, respectively. It is also placed at 4th place in Forbes Asia's Fabulous

50 List of 2010. BHEL was established more than 50 years ago, ushering in the

indigenous Heavy Electrical Equipment industry in India. The company has been

earning profits continuously since 1971-72 and paying dividend since 1976-77. 74% of

the total power generated in India is produced by equipment manufactured by BHEL.

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 CHAPTER 1
ABOUT THE COMPANY

1.1 INTRODUCTION
In 1956 India took a major step towards the establishment of its heavy engineering
industry when Bharat Heavy Electricals Limited, the first heavy electrical
manufacturing unit of the country was set up at Bhopal. It progressed rapidly and three
more factories went into production in 1956 .The aim of establishment BHEL was to
meet the growing power requirement of the country.

BHEL has supplied 97% of the power generating equipment that was
commissioned in India during 1979-80. BHEL has supplied generating equipment to
various utilities capable of generating over 18000MW power. BHEL is one of the
largest power plant equipment manufacturing firms in India and it ranks among the top
ten manufacturers globally. BHEL has covered up many power stations over 40
countries worldwide. BHEL has its headquarters at New Delhi. Its operations are spread
over 11 manufacturing plants and number of engineering and service divisions located
across the country. The service division includes a network of regional offices
throughout India.

Embarking upon the 50th Golden Year of its journey of engineering excellence,
BHEL is an integrated power plant equipment manufacturer and one of the largest
engineering and manufacturing company of its kind in India engaged in the design,
engineering, manufacture, construction, testing, commissioning and servicing of a wide
range of products and services for the core sectors of the economy, viz. Power,
Transmission, Industry, Transportation (Railway), Renewable Energy, Oil & Gas and
Defence with over 180 products offerings to meet the needs of these sectors.
Establishment of BHEL in 1964 was a breakthrough for upsurge in India's Heavy
Electrical Equipment industry. Consistent performance in a highly competitive
environment enabled BHEL attain the coveted 'Maharatna' status in 2013.

BHEL as a part of Pt. Jawaharlal Nehru's vision was bestowed with the onus to
make the country self-reliant in manufacturing of heavy electrical equipment. This

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dream has been more than realised and the contribution in nation building endeavor is
going to continue likewise. Today, with 20,000 MW per annum capacity for power
plant equipment manufacturing, BHEL's mammoth size of operations is evident from its
widespread network of 17 Manufacturing Units, two Repair Units, four Regional
Offices, eight Service Centres, eight Overseas Offices, six Joint Ventures, fifteen
Regional Marketing Centres and current project execution at more than 150 project sites
across India and abroad. The total installed capacity base of BHEL supplied equipment -
138 GW in India speaks volumes about the contribution made by BHEL to Indian
power sector. BHEL's 57% share in India's total installed capacity and 65% share in the
country's total generation from thermal utility sets (coal based) as of March 31, 2014
stand testimony to this. The company has been earning profits continuously since 1971-
72 and paying dividends since 1976-77 which is a reflection of company's
commendable performance throughout.

BHEL, HARIDWAR
a) VISION
A world class Engineering Enterprise committed to Enhancing stakeholder value.
b) MISSION
To be an Indian Multinational Engineering Enterprise providing total Business
solutions through quality products, systems and services in the fields of Energy,
Industry, Transportation ,Infrastructure and other potential areas.
c) VALUES
1. Meeting commitments made to external & internal customers.
2. Foster learning, creativity and speed of response.
3. Respect for dignity and potential of individuals.
4. Loyalty and pride in the company.
5. Team playing.
6. Zeal to excel.
7. Integrity and fairness in all matters.

BHEL, HARIDWAR COMPLEX

a) AREA
BHEL, Haridwar complex consist of two manufacturing units, namely Heavy Electrical

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Equipment Plant (HEEP) and central Foundry, Forge Plant (CFFP). The approximate
area of these plant is a follows:
HEEP: 0.845 sq. km. (Approx.)
CFFP: 1.0 sq. km. (Approx.)
b) LOCATION
BHEL, Haridwar complex is situated in the foot hills of Shivalik range in Haridwar
District of Uttrakhand state. The main Administrative Building is a distance of about
6 km from Haridwar Railway station.

. Fig. 1.1 Plant Main Gate

1.2 BACKGROUND OF THE COMPANY

The first plant of what is today known as BHEL was established nearly 52 years ago at
BHOPAL and was genesis of Heavy Electrical Equipment industry in India. BHEL is
today the largest engineering enterprise of its kind in India, with a well-recognized track
record of performance making profits continuously since 1971-72. It achieved a sales
turnover of Rs.1022 core in 1997-98. BHEL caters to core sectors of the Indian
Economy via, Power, Industry, Transportation, Defence, etc.

The wide network of BHEL’s 14 manufacturing divisions, 9 service centers & 4 power
Sector Regional centers & about 150 project sites enables the service at competitive
prices.

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Having attained ISO 9000 certification, BHEL is now embarking upon the Total Quality
Management. The company’s inherent potential coupled with its strong performance
over the years, has resulted in it being chosen as one of the ― Maharatna PSUs (on 1
February 2013), which are to be supported by the Government in their endeavor to
become future global players. It is the 7th largest power equipment manufacturer in the
world. In the year 2011, it was ranked ninth most innovative company in the world by
US business magazine Forbes. BHEL is the only Indian Engineering company on the
list, which contains online retail firm Amazon at the second position with Apple and
Google at fifth and seventh positions, respectively. It is also placed at 4th place in
Forbes Asia's Fabulous 50 List of 2010.

1.3 ORGANIZATIONAL STRUCTURE

Bharat Heavy Electricals Limited is the largest engineering and manufacturing
enterprise in India in the energy related / infrastructure sector today and ranks among
the top twelve manufacturers of power equipment in the world.

Today BHEL has 14 Manufacturing Divisions, 4 Power Sector regional Centers,

8 Service Centers 18 regional offices and large number of Project Sites spread all over
India and abroad enables the Company to promptly serve its customers and provide
them with suitable products, systems and services efficiently and at competitive prices.
BHEL caters to core sectors of the Indian Economy viz, power generation and
transmission, industry, transportation, renewable energy, defence etc.

BHEL has already attained ISO 9000 and all the major units/divisions of BHEL
have been upgraded to the latest ISO-9001: 2000 version quality standard certification
for quality management. All the major units/divisions of BHEL have been awarded
ISO-14001 certification for environmental management systems and OHSAS-18001
certification for occupational health and safety management systems.

1.3.1 POWER SECTOR

Power sector comprises thermal, nuclear, gas & hydro power plant business. Today,
BHEL supplied sets account for nearly 56,318 MW or 65% of the total installed
capacity of 86,636 MW in as against nit till 1969-1970.

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 BHEL has proven turnkey capabilities for executing power projects from concept
to commissioning. It possess the technology and capability to produce thermal power
plant equipment’s up to 1000MW rating and gas turbine generator sets up to a unit
rating of 240 MW. Cogeneration and combined cycle plants have been introduced to
achieve higher plant efficiencies. To make efficient use of the high ash content coal
available in India, BHEL supplies circulating fluidized bed boilers to thermal and
combined cycle power plants. BHEL manufacturers 235 MW nuclear turbine generator
sets and has commenced production of 500 MW nuclear turbine generator sets. Custom-
made hydro sets of Francis, Pelt on and Kaplan types for different head-discharge
combinations are also engineered and manufactured by BHEL is based upon
contemporary technology comparable to the best in the world & is also internationally
competitive.

1.3.2 TRANSMISSION
BHEL also supplies a wide range of transmission products and systems up to 400 KV
Class. These include high voltage power and distribution transformers, instrument
transformers, dry type transformers, SF6 switchgear, capacitors, and insulators etc. For
economic transmission bulk power over long distances, High Voltage Direct Current
(HVDC) systems are supplied. Series and Shunt Compensation Systems have also been
developed and introduced to minimize transmission losses.

A strong engineering base enables the Company to undertake turnkey delivery

of electric substances up to 400 kV level series compensation systems (for increasing
power transfer capacity of transmission lines and improving system stability and
voltage regulation), shunt compensation systems (for power factor and voltage
improvement) and HVDC systems (for economic transfer of bulk power). BHEL has
indigenously developed the state-of-the-art controlled shunt reactor (for reactive power
management on long transmission lines). Presently a 400 kV Facts (Flexible AC
transmission System) project under execution.

1.3.3 TRANSPORTATION
A high percentage of trains operated by Indian Railways are equipped with BHEL’s
traction and traction control equipment including the metro at Calcutta. The company
supplies broad gauge electrical locomotives to Indian Railways and diesel shunting

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locomotives to various industries.5000/6000 hp AC/DC locomotives developed and
manufactured by BHEL have been leased to Indian Railways. Battery powered road
vehicles are also manufactured by the company.

1.3.4 INTERNATIONAL OPERATIONS

BHEL’s products, services and projects have been exported to over 50 countries
ranging from United States in the west to New Zealand in far East. The cumulative
capacity of power generating equipment supplied by BHEL outside India is over
3000MW. The company’s overseas presence includes projects in various countries. A
few notable ones are : 150 MW (ISOI) gas turbine to Germany, utility boilers and
open cycle gas turbine plants to Malaysia, Tripoli-west, power station in Libya
executed on turnkey basis, thermal power plant equipment to Malta and Cyprus,
Hydro generators to new Zealand and hydro power plant equipment to Thailand.
BHEL has recently executed major gas-based power projects in Saudi Arabia and
Oman, a Boiler contract in Egypt and several Transformer contracts in Malaysia and
Greece.

1.3.5 RENEWABLE ENERGY

Technologies offered by BHEL for non-conventional and renewable sources of energy
include: wind electric generators, solar photovoltaic system, stand alone and grid-
interactive solar power plants, solar heating systems, solar lanterns and battery-powered
road vehicles. The company has taken up R&D efforts for development of multi-
junction amorphous solar cells and fuel cells based systems.

1.3.6 INDUSTRIES
BHEL is a major contributor of equipment and systems to industries: cement, sugar,
fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and process
industries. The company is a major producer of large-size thyristor devices. It also
supplies digital distributed control system for process industries and control &
instrumentation systems for power plant and industrial application. The range of system
& equipment supplied includes: captive power plants, cogeneration plants DG power
plants, industrial steam turbines, industrial boilers and auxiliaries. Water heat recovery
boilers, gas turbines, heat exchangers and pressure vessels, centrifugal
compressors, electrical machines, pumps, valves, seamless steel tubes,

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electrostatic precipitators, fabric filters, reactors, fluidized bed combustion boilers,
chemical recovery boilers and process controls.

The Company is a major producer of large-size thruster devices. It also supplies

digital distributed control systems for process industries, and control & instrumentation
systems for power plant and industrial applications. BHEL is the only company in India
with the capability to make simulators for power plants, defense and other application

1.4 NATURE OF BUSINESS

1.4.1 POWER GENERATION SYSTEMS
i. Turnkey power stations.
ii. Combined-cycle power plants.
iii. Cogeneration systems.
iv. Modernization and rehabilitation of power stations.
v. Erection commissioning, operation and maintenance service
vi. Spares management.
vii. Consultancy services

1.4.2 TRANSMISSION SYSTEMS

i. EHV & UHV Substations/Switchyard.
ii. HVDC transmission systems
iii. Flexible AC Transmission Systems (FACTS) & Smart grid Solutions.
iv. Power system studies.
v. Erection commissioning, operation and maintenance services.
vi. Consultancy services.
vii. Testing facilities.

1.4.3 TRANSPORTATION SYSTEMS

i. Traction systems.
ii. Urban transportation systems
iii. Erection commissioning, operation and maintenance services.
iv. Consultancy services.

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1.5 PRODUCTS
1.5.1 POWER
i. Air Preheaters
ii. Boilers
iii. Control Relay Panels
iv. Electrostatic Precipitators
v. Fabric Filters
vi. Fans
vii. Gas Turbines
viii. Hydro Power Plant
ix. Piping Systems
x. Pulverizes
xi. Pumps
xii. Seamless Steel Tubes
xiii. Soot blowers
xiv. Steam Generators
xv. Steam Turbines
xvi. Turbo generators
xvii. Valves

1.5.2 INDUSTRY
i. Capacitors
ii. Compressors
iii. Desalination Plants
iv. Diesel Generating Sets
v. Industrial Motors & Alternators
vi. Gas Turbines
vii. Oil Field Equipment
viii. Solar Photovoltaic
ix. Power Semiconductor Devices
x. Seamless Steel Tubes
xi. Soot blowers
xii. Steel Castings & Forgings
xiii. Steam Generators

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 xiv. Steam Turbines
xv. Turbo generators
xvi. Valves

1.5.3 TRANSMISSION
Power Transformers/Reactors
i. Instrument Transformers
ii. Switchgears
iii. Control & Protection Equipment’s
iv. Thyristor Equipment’s
v. Insulators
vi. Bushing
vii. Capacitors
viii. Transportation
ix. Electric Rolling Stock
x. Electrics for Rolling Stock
xi. Electrics for Urban Transportation System

1.5.4 NON-CONVENTIONAL ENERGY SOURCE

i. Mini/Micro Hydro Sets
ii. Solar Lanterns
iii. Solar Photovoltaic
iv. Solar Water Heating Systems
v. Wind Electric Generators
vi. R&D Products
vii. Fuel Cells
viii. Surface Coatings
ix. Automated storage & Retrievals
x. Load Sensors
xi. Transparent Conducting Oxide

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 CHAPTER 2
TRAINING ATTENDED

2.1 INTRODUCTION
At the foothills of the majestic Himalayas & on the banks of a holy Ganges in Ranipur
near HARIDWAR is located Heavy Electricals Equipment Plant of Bharat Heavy
electrical Ltd. BHEL, wholly owned by the government of India is an integrated
engineering complex consisting of several plants in India, where about 70,000 workers
are busy in design & manufacturing of a wide range of heavy electrical equipment. At
present 70% of the Country’s electrical energy is generated by the sets manufacturing
by BHEL, Haridwar
BHEL HARDWAR is broadly divided in to two parts:

2.1.1 CFFP (CENTRAL FOUNDRY FORGE PLANT)

CFFP is divided in to following shops:
i. Forge Shop
ii. Machine Shop
iii. Steel Melting Shop (SMS)
iv. Steel Foundry
v. Pattern Shop
vi. Cast Iron (CI) Foundry

2.1.2 HEEP (HEAVY ELECTRICAL EQUIPMENT PLANT)

HEEP is divided into following blocks:
i. BLOCK-1 Turbo Generators, AC Machines
ii. BLOCK-2 Fabrication (Steam, Hydro & gas Turbine)
iii. BLOCK-3 Gas & Steam Turbine
iv. BLOCK-4 CIM (Coil & Insulation Manufacturing) & ACG (Apparatus control
Gear)
v. BLOCK-5 Heat exchangers, Forging and Fabrication
vi. BLOCK-6 Stamping
vii. BLOCK-7 Wooden Packing works
viii. BLOCK-8 Fabrication, seamless tubes and heat exchanger

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 Fig. 2.1 Electrical Machines Block-1

Bharat Heavy Electricals Ltd. (BHEL) Haridwar has two manufacturing plants:-
Heavy Electricals Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP).It
also has a Pollution Control Research Institute, (PCRI).

The 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.

The 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.

The Pollution Control Research Institute (PCRI) provides services in the field of
Environmental Management and Pollution Control in the areas of air, water, noise and
solid waste.

HEEP & CFFP both have been awarded certificates for Quality Systems (ISO-
9001:2008) Environment (ISO-14001) and Occupational Health & Safety (ISO-18001)

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 CHAPTER 3
PROJECT DEVELOPMENT
3.1 INTRODUCTION
3.1.1 TECHNOLOGY / COLLABORATIONS
The technology base of BHEL in the area of steam turbines and Turbo generators has
been created by acquiring technological information from the collaborators. Initially
BHEL had collaboration with M/s LMW USSR for 100 and 210 MW sets. In 1976,
BHEL interred into technical collaboration agreement with M/s Siemens – Kwu,
Germany to acquire the know-how and know-why for turbine generator sets up to 1000
MW. This collaboration still continues. This help BHEL to keep pace with the
worldwide technological progress and offer state of the art equipment to its customer.
Under this collaboration agreement BHEL has established strong design manufacturing
and servicing base for units up to 500 MW ratings.

3.1.2 MANUFACTURING FACILITIES

HEEP Haridwar plant is equipped with most modern and sophisticated machines tools,
facilities and test equipment to manufacture and test generators up to 1000 MW rating,
which include.
a. Most modern micalastic insulation plant for stator bars.
b. Over speed and vacuum balancing tunnel.
c. Kollmann rotor slot milling machine up to maximum barrel length of 7000 mm,
barrel diameter of 1800 mm and rotor weight of 225 tones.
d. Two computerized test beds to test large size generators up to 1000 MW.
e. Wotan CNC horizontal boring machining.
f. Center lathe machine up to maximum length of 16 m and diameter of 3.15 m.
g. Insulation life endurance test assessment facility.

Beside these, HEEP has also set up a Generator Research Institute with an objective to
develop basis know-how and know-why through experimental studies for reliable,
efficient and optimum design of generators and improve their performance in service.

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3.2 TRAINING SECTION OVERVIEW
Block 1: Electrical Machines Block
In block 1 turbo generator and exciter are manufactured. It has 4 Bays, 3 Assembly
section and Test bed.
Bay 1 and 2:- Rotor Shaft, Stator Frame and Stator Core are manufactured. Cutting,
Boring, Finishing and Welding are done on CNC Horizontal and Vertical Boring
Machine.
Bay 3:- Here Exciter is assembled.
Bay 4:- Exciter Pole Coiling and Other small components are manufactured.
For handling and transporting components overhead crane and electric driven transfer
trolleys are used.

3.2.1 ASSEMBLY SECTION

There are three assembly section in block 1.

3.2.2 STATOR ASSEMBLY

Stator parts are assembled here by using different machine. Stator winding is done by
placing stator on rotating installation.

Fig. 3.1 Stator Assembly

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3.2.3 ROTOR ASSEMBLY
Rotor winding coils are assembled in rotor slots. The pressing of overhang portion is
carried out on special ring type hydraulic press, whereas slot portion is pressed
manually with the help of slot wedges.

Fig. 3.2 Rotor Assembly

3.2.4 EXCITER ASSEMBLY

Different Exciter parts are assembled here.

Fig. 3.3 Exciter Assembly

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3.2.5 TEST BED
General assembly of Turbo Generator is done in the test bed. Rotor is inserted in the
stator and assembly of end shields, bearings etc. are carried out to make generator ready
for testing. Turbo Generators are tested as per standards and customer requirements.
New LSTG test bed have the facilities for testing the turbo generator of ratings up to
1000 MW.

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 CHAPTER 4
PROJECT DESCRIPTION & ANALYSIS

4.1 TURBO GENERATOR

The AC generator or alternator is based on the principle of electromagnetic induction
and consist generally of a stationery part called Stator and a rotating part called Rotor.
Stator houses the armature winding. The rotor houses the field winding. DC voltage is
applied to field winding through the slip rings. When the rotor rotates, the lines of
magnetic flux cut through the winding. This induces an electromagnetic EMF in the
stator winding. The magnitude of emf is given by following formula
E = 4.44* ø *ƒ *N volt
Where, ø = strength of magnetic field
ƒ = frequency in hertz
N = number of turn in stator winding

ƒ = frequency = P*n/120 Hz
Where, P = number of poles
n = number of revolution per second of rotor

4.2 FUNCTION OF TURBO GENERATOR

i. The generator rotor is driven by prime mover and on driver side gas/ diesel/ steam
hydro depending on the equipment to which it is meant for.
ii. The non-drive side of rotor is equipped with a rotating side of armature which
produces AC voltage. This is rectified to D C by using a DC commutator / rotating
diode wheel depending upon the type of exciter.
iii. The rear end of above exciter armature is mounted with a permanent magnet
generator rotor.
iv. As the above rotating system put into operation, the PMC produces AC voltage.
v. The voltage is rectified by thyristor circuit to D C.
vi. This supply is given to exciter field. This field is also controlled by taking
feedback from main generator terminal voltage, to control exciter field variation by
automatic voltage regulator. The rectified DC supply out of exciter is supplied to
turbo generator rotor winding either through brushes or central which will be

17
 directly connected to turbo generator. This depends on the type of exciter viz. D C
commutator machines or brushes exciter.
vii. The main AC voltage of generator is finally available to turbo generator stator.

4.3 FEATURE’S OF TURBO GENERATOR

500 MW Turbo generators
Salient technical data:-
i. Rated output : 588 MVA , 500 MW
ii. Terminal voltage : 21 KV
iii. Rated stator current : 16 KA
iv. Rated frequency : 50 Hz
v. Rated power factor : 0.85 Lag
vi. Efficiency : 98.5%

Important Weight and Dimensions:-

i. Rotor weight : 68 Tons
ii. stator dimensions :- 4.l2M(dia)x 8.83M(length)
iii. Rotor dimensions : 1.15M (dia )x 8.5 M( length)
iv. Total weight of turbo generator : 428 Tons

4.4 LARGE STEAM TURBO GENERATOR (LSTG)

These types of generators are those which has taken steam turbine. Their prime mover
and current is supplied by exciter system.
Main types are:-
i. THRI
ii. TARI
iii. T H D I
iv. T H D D
v. T H D F
vi. THFF

Basic terms are:-

T = turbo generator
A = air cooled

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H = hydrogen cooled
R = radial cooling with gas
D = direct axial cooling with gas
F = direct axial cooling with water
I = indirect cooling

4.5 COMPONENTS OF T.G.

STATOR
i. Stator frame
ii. Stator core
iii. Stator winding
iv. End covers
ROTOR
i. Rotor shaft
ii. Rotor winding
iii. Rotor retaining rings.

BEARINGS
COOLING SYSTEM
EXCITATION SYSTEM.

4.5.1 STATOR
The generator stator is a tight construction supporting and enclosing stator winding,
core and hydrogen cooling medium. Hydrogen is contained within frame and circulated
by fans mounted at either end of rotor. The generator is driven by direct coupled steam
turbine at the speed of 3000 rpm.The generator is designed for continuous rated output.
Temperature detector and other device installed or connected within machine, permit
the windings core and hydrogen temperature, pressure, and purity in machine.

4.5.2 STATOR FRAME

Stator body is a totally enclosed gas tight fabricated structure made up of high quality
mild steel and austenitic steel. It is suitably ribbed with annular rings in inner walls to
ensure high rigidity and strength and it also help to reduce vibration and to withstand
the gas thermal pressure .The arrangement, location and shape of inner walls is

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determined by the cooling circuit for the flow of the gas and required mechanical
strength and stiffness. The natural frequency of the stator body is well away from any of
exiting frequencies. Inner and sidewalls are suitably blanked to house for longitudinal
hydrogen gas coolers inside the stator body. It supports the laminated core and winding
the stator comprises an inner frame and outer frame. The inner cage is usually fixed in
the yoke by an arrangement of spring to damper the double frequency vibrations
inherent in two pole generator.

Fig. 4.1 Stator Frame

The fabricated inner cage is inserted in the outer frame after the stator core has been
constructed and the winding completed. Footings are provided the stator foundation
shields enclose the ends of heavy end frame and form mounting of generator bear and
radial shaft. R is subdividing the frame and axial members to form ducts from which the
cooling given to end from radial duct in the core and is recirculated. The horizontally
mounted water cooled gas coolers being so arranged that it may be cleaned on the water
side without opening the machine to atmosphere. All welded joints exposed to
hydrogen are specially made to prevent leakage. The complete frame is subjected to
hydraulic test at a pressure of 7 atm.

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4.5.3 STATOR CORE
It consists of thin laminations. Each lamination made of number of individual segments.
Segments are stamped out with accurately finished die from the sheets of cold rolled
high quality silicon steel. Before insulation on with varnish each segment is carefully
debarred. Core is stacked with lamination segments. Segments are assembled in an
interleaved manner from layer to layer for uniform permeability. Stampings are held in
a position by 20 core bars having dovetail section. Insulating paper pressboards are also
put between the layer of stamping to provide additional insulation and to localize short
circuit. Stampings are hydraulically compressed during the stacking procedure at
different stages. Between two packets one layer of ventilating segments is provided.
Steel spacers are spot welded on stamping.

These spacers from ventilating ducts where the cold hydrogen from gas coolers
enter the core radially inwards there by taking away the heat generated due to eddy
current losses. The pressed core is held in pressed condition by means of two massive
non-magnetic steel castings of press ring. The press ring is bolted to the ends of core
bars. The pressure of the pressure ring is transmitted to stator core stamping through
press fringes of non-magnetic steel and duralumin placed adjacent to press ring. To
avoid-heating of press ring due to end leakage flow two rings made of copper sheet are
used on flux shield. The ring screens the flux by short-circuiting. To monitor the
formation of hot spots resistance transducer are placed along the bottom of slots. To
ensure that core losses are within limits and there are no hot spots present in the core.
The core loss test is done after completion of core assembly.

The main features of core are –

i. To provide mechanical support
ii. To carry efficiently electric, magnetic flux.
iii. To ensure the perfect link between core and rotor.

4.5.4 STATOR WINDING

The stator has a three phase, double layer, short pitched and bar type of windings
having two parallel paths. Each slots accommodated two bars. The slot lower bars and
slot upper are displaced from each other by one winding pitch and connected together
by bus bars inside the stator frame in conformity with the connection diagram. Each bar

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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 conductors of small rectangular cross
section are provided with glass lapped strand insulation. A separator insulates the
individual layers from each other.

The transposition provides for mutual neutralization of voltage induced in the

individual strands due to the slots cross field and end winding field. The current flowing
through the conductor is uniformly distributed over the entire bar cross section reduced.
To ensure that strands are firmly bonded together and give dimensionally stability in
slot portion, a layer of glass tape is wrapped over the complete stack. Bar insulation is
done with epoxy mica thermosetting insulation. This insulation is void free and possess
better mechanical properties. This type of insulation is more reliable for high voltage.
This insulation shows only a small increase in dielectric dissipation factor with
increasing test voltage. The bar insulation is cured in an electrically heated process and
thus epoxy resin fill all voids and eliminate air inclusions.

4.5.5 INSULATION OF BARS

i. Vacuum pressed impregnated mica elastic high voltage insulation:
The voltage insulation is provided according to the proven resin poor mice base of
thermo setting epoxy system. Several half overlapped continuous layer of resin poor
mica tape are applied over the bars. The number of layers or thickness of insulation
depends on the machine voltage. To minimize the effect of radial forces windings hold
and insulated rings are used to support the overhang.

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 Fig. 4.2 Insulation Bars

ii. Corona protection:

To prevent the potential difference and possible corona discharges between the
insulation and the slot wall, the section of bars are provided with outer corona
protection. The protection consists of polyester fluce tape impregnated in epoxy resin
with carbon and graphite as fillers. At the transition from the slot to the end winding
portion of the stator winding portion of stator bars a semiconductor tape made up old
polyester fluce is impregnated.

iii. Resistance temperature detector :

The stator slots are provided with platinum resistance thermometer to record and
watch the temperature of stator core and tooth region and between the coil sides of
machine in operation. All AC machines rated for more than 5 MVA or with armature
core longer the machine is to be provided with at least 6 resistance thermometers of
their couples which shall built inside the stator suitably distributed among the
circumference at the likely hottest point. The thermometer should be fixed in the slot
but outside the coil insulation. When the winding has more than one coil side per slot,

23
 the thermometer is to be placed between the insulated coil sides. The length of the
resistance thermometer depends upon the length of armature. The leads from the
detectors are brought out and connected to the terminal board for connection to
temperature meter or relays operation of RTD is based on the prime that the “electric
resistance of metallic conductor varies linearly with temperature.”

4.5.6 END COVERS

The end covers are made up of fabricated steel or aluminum castings. They are
employed with guide vans on inner side for ensuring uniform distribution of air or gas.

4.5.7 ROTOR
Rotor revolves in most modern generator at speed of 3000 revolutions per minute. It is
also as electromagnet and to give it necessary magnetic strength, the winding must
carry a very high current. The passage of current through windings generates heat. But
the temperature must not be allowed to become too high, otherwise difficulties will be
experienced with insulation. To keep the temperature cross section of the conductors
could not be increased but this would introduce another problems. In order to make
room for large conductor, body and this would cause mechanical weakness. With good
design and great care this problem can be solved.

4.5.8 ROTOR SHAFT

Details of shaft are given here –
Length = 9 meter (approx.)
Diameter = 1 meter (approx.)
Material – alloy steel
Number of poles = 2
The rotor shaft is cold rolled forging 26N1 or MOV116 grade and it is imported from
Japan and Italy.

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 Fig. 4.3 Rotor Shaft

Rotor shaft is a single piece forming manufactured castings. It is forged from a vacuum
cast steel slots for insulation of the field winding are made into the rotor body. The
longitudinal slots are distributed over the circumference. To ensure that a high quality
product is obtained, strength of material analysis and ultrasonic are performed during
the manufacturing rotor. The high mechanical stress resulting from the centrifugal force
and short circuit, torque called for a high specified mechanical and magnetic properties
as well as homogenous forging.

After completion, the rotor is balanced in the various planes and different speed
and then subjected to an over speed test at 120% of rotor speed. The rotor consist of
electrically active portion and two shaft end approximately 60 b% of rotor body
circumference have longitudinal slots which holds the field winding. Slots pitch is
selected so that the two solid poles are displaced by 180 degree the rotor wedges act as
damper winding within the range of winding slots. The rotor teeth at the rotor body are
provided in radial and axial poles enabling cooling air to be discharged.

4.5.9 ROTOR WINDING

The winding consist of several coils inserted into the slots and the series connected such
that two coils group to form one pole. Each coil consist of several series connected turns

25
each of which consist of two half turns connected by brazing in end section. The
individual turn of coil are insulated against each other by interlayer insulation. L-shaped
strip of laminated epoxy glass fiber with nomex filter are used for slot insulation.

The slot wedges are made up of high electrical conductivity material and thus act
as damper winding. At their ends, the slots wedges are short circuited through the rotor
body. When rotor is rotating at high speed, the centrifugal forces tries to lift the winding
out of slots, they are contained by wedges.

4.6 CONSTRUCTION
The field winding consist several series connected coils into the longitudinal slots of
body. The coil are wound that two poles are obtained. The solid conductors have a
rectangular cross-section and are provided axial slots for radial or cooling air. All
conductors have identical copper and cooling section.

4.6.1 CONDUCTOR MATERIAL

The conductors are made up of copper with silver content of approx. 0.1%. As
compared to electrolytic copper silver alloyed copper features high strength properties
at high temperature so that coil deformations due to thermal stresses are eliminated. The
conductors are made of hard drawn silver bearing copper. 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 model

4.6.2 INSULATION
The insulation between the individual turns is made up of layer of glass fiber laminate
the coils are insulated from the rotor body with L-shaped strip of glass fiber laminate
with nomex interlines to obtain the required leakage path between the coil and rotor
body thick top strips of glass fiber laminate are inserted below wedge. The top strip are
provided with axial slots of same cross-section and spacing and used on the rotor
winding.

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4.6.3 END WINDING BRACING
The spaces between the individual’s coils in the end working are with insulated
members that prevent coil movement the insulation by H or L high glass lamination.

4.6.4 ROTOR RETAINING RINGS

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

One end of each ring is shrunk fitted on the rotor body while the other hand
overhangs the end winding without contact on the rotor shaft. This ensures
unobstructed shaft deflection at end windings. The shrunk on hub on the end of the
retaining ring serves to reinforce the retaining ring and serves the end winding in the
axial direction. At the same time, a snap ring is provided against axial displacement of
retaining ring. The shrunk slot of current. To reduce the stray losses and have high
strength, the rings are made up of non-magnetic cold worked material.

4.6.5 ROTOR FANS

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

4.7 BEARINGS
The turbo generators are provided with pressure lubricated self-aligning type bearing to
ensure higher mechanical stability and reduced vibration in operation. The bearings are
provided with suitable temperature element due to monitor bearing metal temperature in
operation.

27
 The temperature of each bearing monitored with two RTD’s (resistance thermo
detector) embedded in the bearing sleeve such that the measuring point is located
directly below Babbitt. These RTDs are monitored temperature scanner in the control
panel and if the temperature exceeds the prescribe limit. Bearing have provision for
vibration pickup to monitor shaft vibration.

To prevent damage to the journal due to shaft current, bearings and coil piping
on either side of the non-drive and bearings are insulated from the foundation frame.
For fascinating and monitoring the healthiness of bearing insulation, shaft insulation is
provided

Fig. 4.4 Bearings

4.8 VENTILAT ION AND COOL ING SYST EM

4.8.1 VENTILATION SYSTEM
The machine is designed with ventilation system having rated pressure. The axial fans
mounted on either side of rotor ensure circulation of hydrogen gas. The rotor is
designed for radial ventilation by stem. The end stator is packets and core clamping and
is intensively cooled by through special ventilation system. Design of special
ventilation is to ensure almost uniform temperature of rotor windings stator core.
Embedded resistance temperature detector do continuous monitoring of hydrogen
temperature at part of generator

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4.8.2 COOLING SYSTEM
4.8.2.1 STATOR COOLING SYSTEM
The stator winding is cooled by distillate water which is fed from one end of the
machine by Teflon tube and flows through the upper bar and returns back through the
lower bar of a slot. Turbo generator requires water cooling arrangement over and above
the usual hydrogen cooling arrangement. The stator is cooled in this system by
circulating demineralized water trough hollow conductors. The cooling was used for
cooling of stator winding and for the use of very high quality of cooling water.

For this purpose DM water of proper specifying resistance is selected.

Generator is to be loaded within a very short period. If the specific resistance of
cooling DM water goes beyond preset value. The system is designed to maintain a
constant rate cooing water flow through the stator winding at a nominal inlet with
temperature of 40 degree centigrade. As it is look working, the cooling water is again
cooled by water which is also demineralized to avoid contamination with any impure
water in case of cooler tube leakage the secondary DM cooling water is in turn cooled
by Clarified water taken from clarified water header.

Fig. 4.5 Stator Cooling System

29
4.8.2.2 ROTOR COOLING SYSTEM
The rotor is cooled by means of gap pickup cooling, where in the hydrogen gas in the
air gap is sucked through the scoops on the rotor and is directed to flow along the
ventilating canals milled on the sides of the rotor coil, to the bottom of slot where it
takes a turn and comes out on the similar canal milled on the other side of the rotor coil
to the hot zone of the rotor, Due to the rotation of the rotor, a positive section as well as
discharge is created due to which a certain quantity of a gas flow and cools the rotor.
The method of cooling gives uniform distribution of temperature. Also this method has
an inherent of eliminating the deformation of copper due to varying temperature.

4.8.3 HYDROGEN COOLING SYSTEM

Hydrogen is used as a cooling medium in large capacity generally in views of high heat
carrying capacity and low density. But in views sits forming an explosive mixture with
oxygen. Proper arrangement for puring, maintaining the purity in the generator have to
be made. Also in order to prevent used hydrogen from generators, casing, and sealing
system is used to provide oil sealing. The system is capable of performing following
system –
1. Filing in and purging of hydrogen safety without bringing in contact with air.
2. Maintaining the gas pressure inside the machine at the desired value at all the
times.
3. Provide indication to the operator about the condition of the gas inside the machine
i.e. the pressure, temperature and purity.
4. Continuous circulation of gas inside the machine through a drier in order to remove
any water vapor that may be present in it
5. Indication of liquid level in the generator and alarm in case of high level.

4.9 GENERATOR SEALING SYSTEM

Seals are employed to prevent the leakage of hydrogen from the stator at the point of
rotor exit. A continuous film between a rotor collar and the seal liner is maintained by
measurement of the oil at pressure above the casing hydrogen gas pressure

30
4.10 EXCITATION SYSTEM
4.10.1 EXCITER
The basic use of given exciter system is to produce necessary DC for turbo generator
system. Principal behind this that PMG is mounted on the common shaft which
generate electricity and that id fed too yoke of main exciter

Fig. 4.6 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 volt for rectifying purpose. We have
for RC bock 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 then it sends the current to rotor as per requirement.

The brushless exciter mainly consists of:-

1. Rectifier wheels
2. Three phase main exciter

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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 brides 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. A common shaft carries the rectifier
wheels the rotor of main exciter and the permanent magnet rotor of pilot exciter. The
shaft is rigidly coupled to generator rotor and exciter rotors are than supported on these
bearings.

4.11 TESTINGS
1. This procedure is for high voltage test on stator winding of turbo generator.
SCOPE – T his procedure covers the high voltage test on stator winding.
PURPOSE – This test is conducted to check whether the insulation is properly placed or
not. The insulation placed over the winding should be such that they make half overlap
with next wrapping of the tape. This test is exclusively conducted to test the health lines
of insulation of winding

2. Test procedure for high voltage on rotor winding of T G.

SCOPE – This produces the high voltage test on rotor winding
PURPOSE – This test is to check whether the insulation is properly placed or not.

3. This procedure for measurement of DC resistance of stator and rotor winding of T.G.
SCOPE – This procedure covers the measurement of DC resistance of stator winding.
PURPOSE – This test is connected to measure the resistance content present in the
conducting material of stator and rotor.

4. Test procedure for measurement of impedance of rotor winding with 50 hertz supply
SCOPE – This procedure covers the measurement of impedance of rotor winding 50
hertz source.

32
5 .Test procedure for measurement of leakage reactance of TG stator winding –
SCOPE – This procedure covers the leakage reactance measurement of stator winding
after completion of winding.
PURPOSE –
i. To determine total leakage reactance Xl.
ii. To determine core leakage reactance Xc.
iii. To compute potier reactance Xd.

6. Test procedure for capacitance measurement of stator winding.

SCOPE – The procedure covers the measurement of capacitance per phase with respect
to ground of the stator winding.
PURPOSE – To generate reference value for comparison in future at site.

PRINCIPLE – The stator winding have two values of capacitances.

i. Cg – capacitance with respect to ground called ground capacitance.
ii. Cm – capacitance with respect to other winding called mutual capacitance.

4.11.1 TEST EQUIPMENTS

1. 50 hertz power frequency AC source
2. AC voltmeter (0-30, 75, 150)
3. AC ammeter (0-5 ampere)
4. Multimeter
5. Current transformer (50/5 A)
6. Connecting leads
7. Power Supply

4.11.2 CALCULATIONS
Z = V/I ohm
Z = Impedance in ohm
V = Voltage in volts
I = Current in ampere

33
With 50 hertz, this test id done in following condition –
1. Rotor outside the stator at standstill.
2. Rotor inside the stator at standstill.
3. Rotor inside the stator at speed 1/3, 2/3, 3/3 of rated speed.

4.11.3 ACCEPTANCE LIMIT

As the impedance of the rotor winding depends on physical geometry of the rotor, it is
not possible to fix at particular value for acceptance, but a peculiar characteristics that
impedance increases with increase of voltage can be assured value of increase is less in
cylindrical rotor that in salient pole rotors .

4.11.4 HELIUM LEAK TEST

To check any leakage of gas from stator and rotor as if there is any leakage of gas used
for cooling such as hydrogen then it may cause an explosion.

34
 CONCLUSION

We have undertaken summer training in Bharat Heavy Electricals Limited, Haridwar.

We undertook project titled “Construction of 800,600,500,250 MW Turbo Generator”.
Training at B.H.E.L. has proved to be quite fruitful. It provided an opportunity to
encounter with such huge machine like turbo-generators

The architecture of B.H.E.L., i.e. the way various units are linked and the
way working of whole plant is controlled make the students realize that Engineering is
not just structural description but greater part is planning and management. It
provided an opportunity to learn various technologies.

We undertook this project and learnt the basics of the construction of turbo
generator by going through every section and basic building blocks of the plant.

Lastly, our training at B.H.E.L. has proved to be satisfactory. It gave us exposure

of the practical implementation of theoretical fundamentals.

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 APPENDIX

1. Generator

The turbo-generator set with all auxiliary systems and accessories shall have following
features/ parameters:

1.1 Type 3-phase, horizontal mounted, 2-pole cylindrical rotor

type, directly driven by steam turbine running at
rated speed conforming to the latest version of IEC-
60034-1, 60034-3 or other equivalent international
standards.
1.2 Rating

i) Rated Output 776MVA for 660 MW or

941 MVA for 800 MW

ii) Power factor 0.85 (lag)

iii) Terminal voltage As per manufacturer’s practice

iv) Frequency 50 Hz

v) Speed 3000 rpm

vi) Short circuit ratio ≥ 0.48

vii) Efficiency > 98%

1.3 Insulation

i) Stator and Rotor Class 155(F) windings

1.4 Operational requirements

Generator shall be capable of delivering rated output under following operational

conditions:

i) Voltage variation (±)5% of rated value at rated power and rated power
factor (as per IEC-60034-3).

ii) Frequency variation (-)5 to (+)3% of 50Hz at rated power and rated
power factor (as per IEC-60034-3).

36
 iii) Combined voltage and 5% (absolute sum).
frequency variation

iv) Power factor variation 0.85 (lag) to 0.95 (lead).

v) Operation under As specified in IEC 60034 -1.

unbalanced load

vi) Operation under I22 t (where I2 and t are negative sequence current in
unsymmetrical short p.u. and time in seconds respectively) to be as per
circuit IEC 60034 – 1.

vii) Voltage waveform Total harmonic distortion (THD) to be within limits

specified in IEC-60034-1.

viii) Short circuit Capable of withstanding of 3-phase short circuit at

withstanding capacity the generator terminals when operating at rated
MVA and power factor with 5% over voltage for a
period of not less than 3 seconds.

ix) Special operating Capable of withstanding the electrical, mechanical

conditions and thermal stresses developed during fast reclosing
of high voltage line, transmission line switching, out
of step operation and out of phase synchronization
etc.

x) Line charging capability Not less than 30% of the rated MVA at zero power
(MVAR) factor leading.

xi) Generator neutral Non-effectively earthed neutral system. Neutral to

earthing be earthed through a distribution transformer loaded
with a resistor. The core design to permit the flow
of earth fault current of at least 15A for 1 second
without major any core damage.

xii) Impulse level and surge Impulse level as per IEC-60034, Pt.15 or as
protection mutually agreed between Manufacturer and the
Purchaser.

37
1.5 Design and constructional features

All components of the generator to be designed to avoid resonance at any of the

frequency in the operating range.

i) Stator Body

Enclosure To withstand without any residual deformation,

any internal hydrogen explosion.
ii) Stator Core

Material High permeability, low loss, cold rolled silicon

sheet steel segmental punchings.
iii) Stator Winding

a) Winding configuration Stator winding consisting of three phase, double

layer, short chorded, bar type winding having two
parallel paths or multiple parallel paths (for
indirect hydrogen cooling), but in case of double
star winding, the total number of terminal bushings
shall be either six (6) or nine (9). The elementary
conductors to be Roebel transposed in the slot
portion.

b) Winding insulation Epoxy thermo – setting type and rated for class
155(F). Provided with adequate protection on the
winding and slots for avoiding the corona and
other surface discharges.

iv) De-mineralized (DM) Water Headers

a) Inlet and outlet water Shall be of stainless steel / SUS/ Copper.

headers

b) Insulation The headers and header connections as per

manufacturer’s standard practice shall be
acceptable and shall be suitably insulated from the
stator body.

v) Stator Winding Connection and Terminal Bushings

a) Winding overhang Overhang portion of winding to be braced and

supported to withstand three phase short circuit at
its terminal as per IEC-60034.

38
 b) Bushing housing To be housed in stator frame in a non-magnetic
steel terminal box or as per proven manufacturer’s
practice.

c) Bushing Porcelain/ epoxy based material with

nonhygroscopic property with suitable cooling
arrangement.

vi) Rotor Machined from a single alloy steel forging to give

the required mechanical, metallurgical and
magnetic characteristics. Shall have an adequate
margin between critical speed and the running
speed to ensure smooth running.
vii) Rotor Winding

a) Conductor Coils made of hard drawn silver bearing copper.

b) Insulation Epoxy glass based material rated for class 155(F)

insulation.

c) Retaining rings Retaining ring of high strength, non-magnetic alloy

steel forging of Mn18Cr18, resistant to stress
corrosion to be provided to prevent the movement
of rotor winding in the radial/ axial direction due to
centrifugal/ thermal stresses.

viii) Bearings

a) Type Self aligning type sleeve/ tilting pad type bearings

either mounted on separate pedestals or on the end
shields. Bearing housings and its shells to be of
split construction. Shells to be lined with tin based
babbitt metal.

ix) Hydrogen Coolers

a) General To be provided with 10% extra tubes. Cooler to be

designed for at least 10 kg/cm2 gauge pressure on
the gas side irrespective of a lower normal
operating casing pressure.

b) Cooler tubes Corrosion resistant with integral fins and arranged

in the stator casing so as to avoid the direct fall of
water during leakage, if any, on the winding
insulation.

39
 REFERENCES

[1]."Annual Report 2012-13" (PDF). BHEL. 14 Aug 2013. Retrieved 29

September 2013.
[2]. http://www.bhel.com/dynamic_files//press_files/pdf/SHP31122014_2.pdf
[3]. https://books.google.co.in/books?isbn=0070593574 Basic Electrical Engineering
2nd Edition - Page 646
[4]. “COMPONENTS OF T.G.” Electrical Machines - I by ASHFAQ HUSAIN

[5]. http://www.gepower.com/prod_serv/products/generators/en/ hydrogen_cool.htm

[6]. “EXCITATION SYSTEM” Electrical Technology - II by B.L.Thereja

40