Context

 Introduction
 History
 Working principle
 Various shops and their work
 Applications of turbo generators
 Conclusion
 Future Scope
 Queries
Overview of BHEL

 BHEL was established in the year 1964 and from the year 1974 it started
earning profits. It has 15 manufacturing divisions,8 service center's across
India.
 BHEL Hyderabad manufactures turbo generators of 1.5MW to 120MW
capacities.
 BHEL has borrowed technology for manufacturing generators from SKODA
Exports Czechoslovakia in1960’s they borrowed from M/s. Siemens,
Germany and it’s sister company KWU(KraftWerk Union) in Germany.
 The Domestic customers of the BHEL in the market are NTPC, ONGC, BPCL,
NFC, Nuclear power corporation, Reliance, Hindustan Oils, oil India, state
electric boards, refineries and cement plants.
Whenever there is a relative motion between a
conductor and magnet, then an EMF is
induced in the conductor. The induced EMF is
directly proportionally to the rate of change of
flux and the no. of turns.
 Definition: A turbo generator is a turbine directly connected to an Electric
generator for the generation of electric power. Large steam powered
turbo generators provide majority of world’s electricity.
 Major components of turbo-generators are the Active Parts and the
support parts. Stator winding, Rotor winding, Stator core comes under the
active parts and stator frame, rotor shaft, rotor retaining rings, Cooling
and excitation systems come under the support parts.
 Active parts:  Support parts:
 Stator core.  Stator frame.
 Stator winding.  Rotor shaft.
 Stator end cover.  Rotor retaining rings.
 RTD’S.  Bearings.
 Rotor winding.  Cooling system.
 Excitation system.
Steps in designing process of a turbo
generator

 Press shop  Balancing

 Light Machine shop  VPI plant
 Heavy machine shop  Assembly
 Copper shop  Testing
 Coil shop
 Insulation shop
 Rotor winding
 Stator winding
Press shop

 Silicon steel rolls are checked for

chemical, mechanical, electrical
and magnetic properties as per the
specifications.
 They are then subjected to notching.
 Varnishing:-After completion and
processing of lamination, the sheets
are varnished.
Coil shop

 Reception of conductor rolls

 Conductors cutting
 Transposition
 Cleaning an finishing of stator coils.
 Final taping
Copper shop

 Reception of copper conductors

 Ventilation punching
 Chamfering
 Edge wise bending
 Annealing
 Corner pressing
 Radius Formation and Brazing
Rotor windings

 Reception of rotor
 Laying of coils
 Centring of coils with respect to rotor
 Assembly of retaining rings
Balancing

 The assembled rotor is subjected to

the following stages of balancing:
 Low speed balancing
 High speed balancing
 Over speed test
 Performance of heat cycles
 Final balancing
VPI Plant
 Vacuum Pressure Impregnation (V.P.I)
is a process by which a fully wound
electric apparatus stator or rotor is
completely submerged in a Resin.
 The process is used primarily for high-
voltage motors and generators to fill
gaps in materials to create a void free
insulation in various devices.
 Advantages of VPI insulation system:
 Increased winding lifespan.
 Higher coil rigidity and stability.
 Increased performance in harsh,
abrasive and corrosive environments.
 Better heat transfer.
Stator core

 Stator core is made of insulated steel

laminations.
 The thickness of the laminations and
the type of steel are chosen to
minimize eddy current and hysteresis
losses.
 This enormous mass of steel segments
is aligned and held together under
compressive load with components
such as key bars, building bolts,
through bolts, finger plates, and
compression rings.
Stator winding

 The stator winding is of short chorded

pitch, double layer lap-bar type
construction.
 The stator bars are composed of
varnished and glass covered copper
strips.
 The stator winding is of short chorded
pitch, double layer lap-bar type
construction. The stator bars are
composed of varnished and glass
covered copper strips.
Final Assembly of Turbo Generator
Applications of turbo generators

 It can be generated by renewable

energy sources which are
environment friendly.
 Life span of the machine is long.
 Economic in cost compared to other
generators, hence in U.S. 90% of
electrical generation is done by turbo
generators.
Conclusion

 As turbo generators are high voltage machines which are ranging from
less than 1500 volts, hence the machine efficiency is accurate.
 Turbo generators are more reliable in nature. As the production of sources
are taken from the non renewable energy sources the cost is economic.
 The scientists are investigating and testing on different insulation
techniques besides VPI technique of turbo generators.
Thank you.