BHARAT HEAVY ELECTRICALS LIMITED

HARIDWAR
VOCATIONAL TRAINING REPORT
Submitted toMr.Satish Kumar Singh
(Sr. Engineer, Electrical Machines, Planning)

Submitted byMohd Uzair Khan

1312101085
B.Tech (EE)

[1]

ACKNOWLEDGEMENT
I would like to express my gratitude for the people who were part of this Project
Report, directly or indirectly people who gave unending support right from the
stage the idea was conceived.
In particular I would like to thanks to Mr.Satish Kumar Singh (Sr. Engineer,
Electrical Machines, Planning) in BHEL, Haridwar for providing me with an
opportunity to undergo training under his able guidance.
I whole hearted appreciate the atmosphere provided to me by the staffs of
Electrical Engineering. The data has been collected at primary source through
discussions with officers of different sections. For this nice gesture on their part,
I shall ever remain obliged to them.

[2]

CONTENT
1. Overview of BHEL
2. Different Blocks at HEEP
3. Block-1 Electrical Machines
4. Turbo Generator
5. Constructional features of Stator Body
6. Constructional features of Stator core
7. Constructional features of stator Winding
8. Constructional features of Rotor
9. Cooling System
10. Excitation System
11.Electrical generator Protection
12. CIM (Block-4)
13. ACM(Block-4)

[3]

OVERVIEW OF BHEL
The first plant of which is today known as BHEL was established nearly 50 years ago
at Bhopal & was the genesis of the Heavy Equipment industry in India. BHEL is
today the largest Engineering Enterprise of its kind in India with excellent track record
of performance, making profits continuously since 1971-1972.
BHEL business operations cater to core sectors of the Indian Economy like
Power
Industry
Transportation
Transmission etc.
BHEL has 14 units spread all over India manufacturing boilers, turbines, generators,
transformers, motors etc. Besides 14 manufacturing divisions the company has 4
power sector regional centers, 8 service centers and 18 regional offices and a large
number of project sites thus enable the Company to promptly serve its customers and
provide them with suitable products, systems and services efficiently and at
competitive prices. The high level of quality & reliability of its products is due to the
emphasis on design, engineering and manufacturing to international standards by
acquiring and adapting some of the best technologies from leading companies in the
world, together with technologies developed in its own R&D centers. BHELs vision
is to become world-class engineering enterprise, committed to enhancing stakeholder
value. The company is striving to give shape to its aspirations and fulfill the
expectations of the country to become a global player.
Two manufacturing plants of BHEL: Heavy Electrical Equipment Plant (HEEP) and
Central Foundry Forge Plant (CFFP) employing about 10000 people.
Heavy Electrical Equipment Plant is equipped to produce Steam and Hydro Turbines
with matching Generators; Industrial Manufacturing Thermal sets up to 1000 MW
capacity.
The Heavy Electrical Equipment Plant was set up in technical collaboration with
(Union of Soviet Socialist Republics) USSR. The construction of the plant
commenced in 1962 and the production of equipment was initiated in early 1967. In
1976, BHEL entered into a collaboration agreement with West Germany for design,
manufacture, erection and Commissioning of large size steam turbines and turbo
generators of unit rating up to 1000MW.
The BHEL plants in Haridwar have earned the ISO-9001 AND 9002 certificates for
its high quality and maintenance. These two units have also earned the ISO-14001
certificates.

[4]

BHEL is the largest engineering and manufacturing enterprise in India in the energy
related infrastructure sector today. The wide network of BHEL's 14 manufacturing
division, four power Sector regional centers, over 150 project sites, eight service
centers and 18 regional offices, enables the Company to promptly serve its customers
and provide them with suitable products, systems and services efficiently and at
competitive prices. While the company contributes more than 75% of the national
grid, interestingly a share of 45% comes from its single unit. And this is none other
than BHEL-HARIDWAR
BHEL has: Installed equipment for over 90,000MW of power generation--- for utilities
captive and industrial users.

Supplied over 2, 25,000 MVA transformer capacity and other equipment

operating in transmission and distribution network up to 400 kV (AC & DC).

Supplied over 25,000 motors with drive control systems to power projects,
petrochemicals, refineries, steel, aluminum, fertilizers, cement plants etc.

Supplied Traction electrics and AC/DC locos to power over 12,000 kMs railway
network.

Supplied over one million valves to power plants and other industries

POWER SECTOR
Power generation sector comprises thermal, gas, hydro and nuclear power plant
business .BHEL supplied utility sets accounts to 87,646 MW 65% of the total installed
capacity of 1,38,175 MW in the country , as against nil in 1969 -70. As part of Indias
largest Solar Power-based Island Electrification Project in India, Bharat Heavy
Electricals Limited (BHEL) has successfully commissioned two Grid-Interactive Solar
Power Plants of 100 KW each in Lakshadweep.
With this, the company has commissioned a total of eleven Solar Power Plants in the
Lakshadweep islands, adding over 1 MW of Solar Power to the power generating
capacity of the coral islands in the Arabian Sea.
BHEL has proven turnkey capabilities for executing power projects from concept
to commissioning and manufactures boilers, thermal turbine generator sets and
auxiliaries up to 500MW.
It possesses the technology and capability to procure thermal power generation up
to 1000MW.
Co- generation and combined cycle plants have also been introduced.
BHEL manufacturers 235MW nuclear sets and has also commenced production of
500MW nuclear turbine generator sets.

[5]

Custom made hydro sets of Francis, peloton and Kaplan types for different head
discharge combination are also engineering and manufactured by BHEL.
In, all 700 utility sets of thermal, hydro, gas and nuclear have been placed on the
company as on date. The power plant equipment manufactured by BHEL is based on
contemporary technology comparable to the best in the world and is also
internationally competitive.
The Company has proven expertise in Plant Performance Improvement through
renovation modernization and up rating of variety of power plant equipment besides
specialized know how of residual life assessment, health diagnostics and life extension
of plants.

POWER TRANSMISSION AND DISTRIBUTION (T&D)

BHEL offer wide-ranging products and systems for T & D applications Products.
They manufactured include power transformers, instrument transformers, dry type
transformers, series and shunt reactor, capacitor tanks, vacuum and SF6 circuit
breakers gas insulated switch gears and insulators.
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.

INDUSTRY SECTOR
BHEL is a major contributor of equipment and system to important industries like
Cement
Petrochemicals
Fertilizers
Steel papers
Refineries
Mining and telecommunication

[6]

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) projects is under execution.
The range of system and equipment supplied includes: Captive power plants
High speed industrial drive turbines
Industrial boilers and auxiliaries
Waste heat recovery boilers
Gas turbine pump, valves, seamless steel tubes
Heat exchangers
Process control etc.

TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production,
installation, and maintenance and after-sales service of Rolling Stock and traction
propulsion systems. In the area of rolling stock, BHEL manufactures electric
locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP,
both for mainline and shunting duly applications. BHEL is also producing rolling
stock for special applications viz., overhead equipment cars, Special well wagons,
Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use,
BHEL manufactures traction propulsion systems for other rolling stock producers of
electric locomotives, diesel-electric locomotives, electrical multiple units and metro
cars. The electric and diesel traction equipment on India Railways are largely powered
by electrical propulsion systems produced by BHEL. The company also undertakes
retooling and overhauling of rolling stock in the area of urban transportation systems.
BHEL is geared up to turnkey execution of electric trolley bus systems, light rail
systems etc. BHEL is also diversifying in the area of port handing equipment and
pipelines transportation systems.

TELECOMMUNICATIONBHEL also caters to telecommunication sector by way of small, medium and large
switching system.

[7]

DIFERENT BLOCKS AT HEEP

BLOCK-1: ELECTRICAL MACHINES
Facilities: Machine Shop. Windings bar preparation assembling, painting section,
packing& preservation, over speed balancing, test bed test stand, babbiting, micalastic
impregnation etc.
Products: Turbo Generator, Generator exciters, motors (AC& DC)

BLOCK-2: FABRICATION BLOCK

Facilities: Markings, welding ,Cutting, straightening, gas cutting press, , grinding,
assembly, heat treatment, cleaning & Shot blasting, machining, fabrication of pipe
coolers, painting
Products : Large size fabricated assemblies/ components for power equipments

BLOCK-3: TURBINES & AUXILIARY BLOCK

Facilities: Machining, facing wax melting, broaching, assembly preservation &
packing, test stands/ station, painting grinding, milling, polishing etc.
Products: Stem turbines, hydro turbines, gas turbines, turbine bladders, special
tooling

BLOCK-4: FEEDER BLOCK

Facilities: Bar winding, mechanical assembly, armature winding, sheet metal working
marching, copper profile drawing electroplating, impregnation, machining &
preparation of insulating components plastic molding, press molding
Products: Windings for turbo generators, hydro generators insulation for AC & DC
motors, insulating components for TG, HG & Motors control panel, contact relays
master control etc.

BLOCK-5: CONDENSER FABRICATION & FORGE BLOCK

Facilities: Fabrication, pneumatic hammer for forgings, gas fired furnaces, hydraulic
manipulators
Products: Fabricated parts of steam turbine, water box, storage tank hydro turbine
parts, hydro turbines assemblers & Components

BLOCK-6: STAMPING & DIE MANUFACTURING

Facilities: Welding, drilling, shot blasting, CNC flame cutting, CNC deep drilling,
Shot basting, sheet metal work, assembly
Products: Wooden packing, spacers etc.

[8]

BLOCK-7: CARPENTRY SHOP

Facilities: Wood Cutting, machines, grinding , packing Wooden packing, spacers etc.
Products: Wooden packing, spacers etc.

BLOCK-8: HEAT EXCHANGE SHOP

Facilities: Drilling ,turning, saw, cutting, welding, tig welding
Products: LP Heater ejectors glad, steam cooler oil coolers, ACG collers, oil tanks,
bearing covers

SERVICE PLAT
Facilities: TPS: Power generation equipment & auxiliaries plat capacity 12 MWPower generation
PGP Plat: Boiler Type gas generators- Producer gas
Acetylene Plat: A fully automated plant for acetylene generation & filling in cylinderAcetylene gas
Compressor House: 4 No. Compressors of rating 100 m2 / min-Compressed air
Oxygen Plat: 3 air separation unit 4 air compressors-Oxygen gas & Nitrogen gas
132 KV substation: 2 Nose 16.7 MVA/ 11 KV, one no. 20 MVA & one no. 12.5
MVA 132/6.6 KV transformer & other allied equipment-Power supply

MOTOR TRANSPORT
Facilities: A fleet of vehicles comprising of cars, jeeps trekkers, buses, mini buses
motorcycles, fire tenders trucks etc.

TELECOMMUNICATION
Facilities: Telephone service

HYDROTURBINE LAB
Facilities: 3 test beds with electronic instrumentation. It consists of cavitations test
bed for reactions turbine & hydrodynamic test bed for Impulse turbines facilities for
carrying out filed test at hydro power sets
Products: Testing of turbine models

HRDC
Facilities: Training to Employees, VTs Apprentices, Contractors & Customers

ENGINEERING
Facilities: Design and drawings of all products

[9]

COMPUTER CENTRES
Facilities: ICIMs series 39 DX level 270-320 computer system HCL magnum mini
compute system , ESPL SM 32 minicomputer Nexus 3500 CAE work station, PCs
etc.

CPL (CENTRAL PLANT LAB)

Facilities: Testing Lab for new materials & sample components

POLLUTION CONTROL RESEARCH INSTITUTE

To provide directional thrust to environmental control / protection activities, a
Pollution Control Research Institute has been set up by BHEL at HEEP, Haridwar
with the assistance of United Nations Development Programme (UNDP).
The main objective of the Institute is to develop technologies for pollution control in
the areas of air, water noise and solid waste to obviate unintended side effects of
economic growth. The Institute is concentrating on research and development
activities related to environment protection against pollution emanating from
industries. PCRI provides consultancy services related to pragmatic approaches /
methods to maintain pollution within permissible limits. The other objectives include
development of methods for recovery and recycling of industrial wastes.
Most modern facilities for monitoring and analysis in the area of air, water, noise and
solid waste are available at the Institute. It has full-fledged computer facilities for
prediction and forecasting pollution impact. It also has workshop and other support
services.
The laboratories of Pollution Control Research Institute have been recognized by
Ministry of Environment and Forests, Govt. of India; Department of Science and
Technology, Govt. of India; Madhya Pradesh Pradushan Nivaran Mandal; UP State
Pollution control Board; Bihar State Pollution Control Board; Punjab State Council
for Technology; Haryana State Pollution Control Board; Karnataka State Pollution
Control Board.

[10]

BLOCK-1: ELECTRICAL MACHINES

1. Block-I is designed to manufacture Turbo Generators.
2. The block consists of 4 bays- Bay-I (36*482 meters), Bay-II (36*360 meters) and
Bay-III and Bay-IV (Of size 24*360 meters each).
3. For handling and transporting the various components over-head crane facilities
are available, depending upon the products manufactured in each Bay. There are
also a number of self-propelled electrically driven transfer trolleys for the inter-bay
movement of components/assemblies.
4. Testing facilities for Turbo generator are available in Bay-II.
5. There is a special test bed area for testing of T.G. of capacity of 500 MW Unit
sizes.
BAY-1

ROTOR SHAFT
MACHINING

ROTOR SHAFT
SLOTTING

ROTOR
WINDING

OVER SPEED AND

BALANCING
TUNNEL

LARGE
SIZE
T.G

BAY-2

EXCITER
SHAFT
MACHINEING

STATOR BODY
MACINING

STATOR
WINDING

TOTAL
IMPREGNATION

TEST
BED

BAY-3

ROTOR
SUPPORT
BEARING
COOLING
FANS
MACHINING

SHAFT SEAL
BODY

DC
MOTOR
WINDING

BAY-4

ARRANGMENT
& OTHER PARTS

BASIC TURBO GENERATOR DEPARTMENTS:

MACHINE SHOP.
T/G ROTOR WINDING.
H/G IRON ASSEMBLY.
EXCITER.
T/G STATOR WINDING.
TOTAL IMPREGNATION TECHNIQUE.
T/G IRON ASSEMBLY.
T/G MAIN ASSEMBLY.
L.S.T.G ROTOR WINDING.
L.S.T.G STATOR WINDING.
L.S.T.G MAIN ASSEMBLY.
TEST BED.

[11]

MANUFACTURING PROCESS
Fabricated components are received in respective machine sections from Fabrication
blocks (Block II, V, VI, VIII), while castings and forgings are received from sister
unit CFFP and other indigenous and foreign sources for Turbo Generators. Stampings
are received from stampings manufacture block, blockVI and coils, bars, insulating
details and sheet metal components are received from coils and insulation
manufacture and apparatus and control gear box (block IV).

Turbo Generators

Making of blanks is done for checking the availability of machining allowances.

Machining of the major components is carried out in Bay - I & Bay- II and other
small components in Bay - III and Bay - IV. The boring and facing of stators are
done on CNC horizontal boring machine using a rotary table. The shaft is turned
on lathe having swift 2500 mm and the rotor slots are milled on a special rotor slot
milling machines.
In case of large size Turbo Generators core bars are welded to stator frame with
the help of telescopic centering device. The centering of core bar is done very
precisely. Punching are assembled manually and cores are heated and pressed in
number of stages depending on the core length.
Stator winding is done by placing stator on rotating installation. After laying of
lower and upper bars, these are connected at the ends, with the help of ferrule and
then soldered by resistance soldering.
Rotor winding assembly is carried out on special installation where coils are
assembled in rotor slots. The pressing of overhang portionis carried out on special
ring type hydraulic press, whereas slot portion is pressed manually with the help of
rotor wedges. Coils are wedged with special press after laying and curing. The
dynamic balancing of rotors is carried out on the over speed balancing installation.
500 MW Turbo Generators are balanced in vacuum balancing tunnel.
General assembly of Turbo Generators is done in the test bed. Rotor is inserted in
the stator and assembly of end shields; bearings etc. are carried out to make
generators ready for testing. Prior to test run the complete generator is
hydraulically tested for leakages. Turbo Generators are tested as per standard
practices and customer requirements.

[12]

TURBO GENERATOR
A turbo generator is the combination of a turbine directly connected to an electric
generator for the generation of electric power. Large steam turbo generators provide
the majority of the world's electricity and are also used by steam-powered turboelectric ships .Smaller turbo-generators with gas turbines are often used as auxiliary
power units. For base loads diesel generators are usually preferred, since they offer
better fuel efficiency, but, on the other hand, diesel generators have a lower power
density and hence, require more space.it 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* **N volt.

WORKING PRICIPLE OF TURBO GENERATOR

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.
The non-drive side of rotor is equipped with a rotating side of armature which
produces AC voltage. This is rectified to DC by using a DC. Commutator / rotating
diode wheel depending upon the type of exciter.
The rear end of above exciter armature is mounted with a permanent magnet
generator rotor.
As the above rotating system put into operation, the PMC produces AC voltage.
The voltage is rectified by Thyristor circuit to DC.
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
directly connected to turbo generator. This depends on the type of exciter viz. DC
Commutator machines or brushes exciter.
The main AC voltage of generator is finally available to turbo generator stator.

[13]

LARGE SIZE TURBO GENERATOR (LSTG)

These types of generators are those which have taken steam turbine. Their prime
mover and current is supplied by exciter system.
Main types are:

THRI
TARITHDI
THDD
THDF
THFF

Basic terms are:T = turbo generator

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

500 MW Turbo generators at a glance 2-Pole machine with the following features:

Direct cooling of stator winding with water.

Direct hydrogen cooling for rotor.
Micalastic insulation system
Spring mounted core housing for effective transmission of vibrations.
Brushless Excitation system.
Vertical hydrogen coolers

Salient technical data

Rated output : 588 MVA , 500 MW

Terminal voltage : 21 KV
Rated stator current : 16 KA
Rated frequency : 50 Hz
Rated power factor : 0.85 Lag
Efficiency : 98.55%

[14]

Important dimensions & weights Heaviest lift of generator stator : 255 Tons
Rotor weight : 68 Tons
Overall stator dimensions [LxBxH] : 8.83Mx4.IMx4.02M
Rotor dimensions : 1.15Mdia x 12.11 M length
Total weight of turbo generator : 428 Tons
Unique installationsHeavy Electrical Equipment Plant, Haridwar is one of the best equipped and most
modern plants of its kind in the world today. Some of the unique manufacturing and
testing facilities in the plant are:
TG Test BedNew LSTG [Large Scale Turbo Generator] Test Bed has been put up with indigenous
know-how in record time for testing Turbo generators of ratings 500MW and above
up to 1000 MW. It caters to the most advanced requirement of testing by employing
on-line computer for data analysis.

Other major facilities are as followsOver speed Balancing vacuum tunnel

For balancing and over speeding large flexible Turbo generators rotors in vacuum for
ratings up to 1,000 MW, an over speed and balancing tunnel has been constructed
indigenously. This facility is suitable for all types of rigid and flexible rotors and also
high speed rotors for low and high speed balancing, testing at operational speed and
for over speeding.

Generator transportation

Transport through300 Tons 24-Axle carrier beam railway wagon specially designed
indigenously and manufactured at Haridwar.
The wagon has been used successfully for transporting one generator -from Calcutta
Port to Singrauli STPP.

CONSTRUCTIONAL FEATURES OF STATOR BODY

1. 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 .The arrangement, location and shape of inner walls
is 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

[15]

of exiting frequencies. Inner and sidewalls are suitably blanked to house for
longitudinal hydrogen gas coolers inside the stator body.

2. Pipe Connection To attain a good aesthetic look, the water connection to gas cooler is done by routing
stainless steel pipes; inside the stator body; which emanates from bottom and emerges
out of the sidewalls.
These stainless steel pipes serve as inlet and outlet for gas coolers.
From sidewall these are connected to gas coolers by the means of eight U-tubes
outside the stator body. For filling the generator with hydrogen, a perforated manifold
is provided at the top inside the stator body.

3. Terminal Box The bearings and end of three phases of stator winding are brought out to the slip-ring
end of the stator body through 9 terminals brushing in the terminal box. The terminal
box is a welded construction of (nonmagnetic) austenitic steel plates. This material
eliminates stray losses due to eddy currents, which may results in excessive heating.

4. Testing Of Stator Body On completion of manufacture of stator body, it is subjected to a hydraulic pressure of
8 kg/cm for 30 minutes for ensuring that it will be capable of withstanding all
expansion pressure, which might arise on account of hydrogen air mixture explosion.
Complete stator body is then subjected to gas tightness test by filling in compressed
air.

CONSTRUCTIONAL FEATURES STATOR CORE

1. 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

[16]

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.

2. Core SuspensionThe elastic suspension of core consist of longitudinal bar type spring called core bars.
Twenty core bars are welded to inner walls of stator body with help of brackets. These
are made up of spring steel having a rectangular cross section and dove-tail cut at tap,
similar type of dovetail is also stamped on to stamping and fit into that of core bar
dovetail. Thus offering a hold point for stamping core bars have longitudinal slits
which acts as inertial slots and help in damping the vibrations. The core bars are
designed to maintain the movement of stator core with in satisfactory limits.

CONSTRUCTIONAL FEATURES OF STATOR WINDING

1. General
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.

2. Conductor ConstructionEach 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 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

[17]

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.

3. Method of Insulation Bar is tapped with several layers of thermosetting epoxy tape. This is applied
continuously and half overlapped to the slot portion. The voltage of machine
determines the thickness of insulation. The tapped bar is then pressed and cured in
electrical heated press mould for certain fixed temperature and time.

4. Corona PreventionTo prevent corona discharges between insulation and wall of slots, the insulation in
slot portion is coated with semiconductor varnish. The various test for manufacture
the bar is performed which are as follows
Inter turn insulation test on stuck after consolidation to ensure absence of inter
short.
Each bar is subjected to hydraulic test to ensure the strength of all joints
Flow test is performed on each bar to ensure that there is no reduction in cross
section area of the ducts of the hollow conductor.
Leakage test by means of air pressure is performed to ensure gas tightness of all
joints.
High voltage to prove soundness of insulation.
Dielectric loss factor measurement to establish void free insulation.

5. Laying Of Stator Winding The stator winding is placed in open rectangular slots of the stator core, which are
uniformly distributed on the circumference. A semi conducting spacer is placed in
bottom of slots to avoid any damage to bar due to any projection. Driving in semi
conducting filler strips compensates any manufacturing tolerances. After laying top

[18]

bar, slot wedges are inserted. Below slots wedges, high strength glass texolite spacers
are put to have proper tightness. In between top and bottom bars, spacers are also put.

6. Ending Winding In the end winding, the bars are arranged close to each other. Any gaps due to design
or manufacturing considerations are fitted with curable prepag with spacer in between.
The prepag material is also placed between the brackets and binding rings. Lower and
upper layers are fixed with epoxy glass ring made in segment and flexible spacer put
in between two layers. Bus bars are connected to bring out the three phases and six
neutrals. Bus bars are also hollow from inside. These bus bars are connected with
terminal bushing. Both are water-cooled. Brazing the two lugs properly makes
connection.

CONSTRUCTIONAL FEATURES OF ROTOR

The rotor comprises of following component:
1.
2.
3.
4.
5.
6.

Rotor shaft
Rotor winding
Rotor wedges and other locating parts for winding
Retaining ring
Fans
Field lead connections

1. Rotor Shaft
The rotor shaft is a single piece solid forging manufactured from a vacuum casting.
Approximately 60 % of the rotor body circumference is with longitudinal slots, which
hold the field winding. The rotor shaft is a long forging measuring more than 9m
inlength and slightly more than one meter in diameter.
The main constituents of the steel are chromium, molybdenum, nickel and vanadium.
The shaft and body are forged integral to each other by drop forging process.
Following tests are done: (A) Mechanical test

Chemical analysis
Magnetic permeability test
Micro structure analysis
Ultrasonic examination
Boroscope examination

[19]

On 2/3 of its circumference approximately the rotor body is provided with

longitudinal slot to accommodate field winding. The slot pitch is selected in such a
way that two solid poles displaced by 180o C are obtained. For high accuracy the rotor
is subjected to 20% over speeding for two minutes. The solid poles are provided with
additional slots in short lengths of two different configurations.
One type of slots served as an outlet for hydrogen which has cooled the overhang
winding and other type used to accommodate finger of damper segments acting as
damper winding.

2. Rotor Winding

After preliminary turning, longitudinal slots are milled on sophisticated horizontal slot
milling machine. The slot house the field winding consists of several coils inserted
into the longitudinal slots of rotor body2.1 Copper ConductorThe 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.
2.2 Insulation The individual turns are insulated from each other by layer of glass prepag 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. These liners are
made from molding material. The overhang winding is separated by glass laminated

[20]

blocks called liners. The overhang winding are insulated from retaining rings
segments having L-shape and made of glass cloth impregnated by epoxy resin.
2.2 Cooling Of WindingThe rotor winding are cooled by means of direct cooling method of gap pick-up
method. In this type of cooling the hydrogen in the gap is sucked through the elliptical
holes serving as scoop on the rotor wedges and is directed to flow along lateral vent
ducts on rotor cooper coils to bottom of the coils. The gas then passes into the
corresponding ducts on the other side and flows outwards and thrown into the gap in
outlet zones.
In this cooling method the temperature rise becomes independent of length of rotor.
The overhang portion of the winding is cooled by axial twosystems and sectionalized
into small parallel paths to minimize temperature rise.
Cold gas enters the overhang from under the retaining rings through special chamber
in the end shields and ducts under the fan hub and gets released into the air gap at
rotor barrel ends.

3. Rotor Wedges For protection against the effect of centrifugal force the winding is secured in the slots
by slot wedge. The wedges are made from duralumin, an alloy of copper, magnesium
and aluminum having high good electrical conductivity and high mechanical strength.
The wedges at the ends of slot are made from an alloy of chromium and copper. These
are connected with damper segments under the retaining ring for short circuit induced
shaft current. Ventilation slot wedges are used to cover the ventilation canals in the
rotor so that hydrogen for overhang portion flows in a closed channel.

4. Retaining Ring The overhang portion of field winding is held by non-magnetic steel forging of
retaining ring against centrifugal forces. They are shrinking fitted to end of the rotor
body barrel at one end; while at the other side of the retaining ring does not make
contact with the shaft. The centering rings are shrinking fitted at the free end of
retaining ring that serves to reinforce the retaining ring, securing, end winding in axial
direction at the same time. To reduce stray losses, the retaining rings are made of nonmagnetic, austenitic steel and cold worked, resulting in high mechanical strength.

[21]

5. Fans
Two single stage axial flow propeller type fans circulate the generator cooling gas.
The fans are shrinking fitted on either sides of rotor body.
Fans hubs are made of alloy steel forging with three peripheral grooves milled on it.
Fan blades, which are precision casting with special alloy, are machined in the tail
portion so that they fit into the groove of the fan hub.

6. Field Lead Connections

Slip Rings The slip ring consists of helical grooved alloy steel rings shrunk on the body shaft and
insulated from it. The slip rings are provided with inclined holes for self-ventilation.
The helical grooves cut on the outer surfaces of the slip rings improve brush
performance by breaking the pressurized air pockets that would otherwise get formed
between the brush and slip rings.

Field Lead The slip rings are connected to the field winding through semi flexible copper leads
and current-carrying bolts placed in the shaft. The radial holes with current carrying
bolts in the rotor shafts are effectively sealed to prevent the escape of hydrogen. A
field lead bar, which has similar construction as, does the connection between current
carrying bolt and field winding that of semi flexible copper leads (they are insulated
by glass cloth impregnated with epoxy resin for low resistance and ease of assembly).

COOLING SYSTEM
Heat losses arising in generator interior are dissipated to secondary coolant (raw
water, condensate etc.) through hydrogen and Primary water. Direct cooling
essentially eliminates hot spots and differential temperature between adjacent
components, which could result in mechanical stresses, particularly to the copper
conductors, insulation, and rotor body and stator core.

Hydrogen Cooling Circuit:

The hydrogen is circulated in the generator interior in a closed circuit by one
multistage axial flow fan arranged on the rotor at the turbine end. Hot gases is drawn

[22]

by the Ian from the air gap and delivered to the coolers where it is re-cooled and then
divided into three flow paths after each cooler:

Flow path I:
Flow path I is directed into the rotor at the turbine end below the fan hub for cooling
of the turbine end half of the rotor.
Flow path II:
Flow path H is directed from the cooler to the individual frame compartments for
cooling of the stator core.
Flow path III:
Flow path III is directed to the stator end winding space at the exciter end through
guide ducts in the frame of cooling of the exciter end half of the rotor and of the core
end portion. The three flow paths miss the air gaps. The gas is then returned to the
coolers via the axial flow fan. The cooling water flow through the hydrogen coolers
should automatically control to maintain a uniform generator temperature level for
various loads and cold-water temperature.

Cooling Of Rotors:
For direct cooling of rotor winding cold 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.

Cooling of stator core:

For cooling of the stator core, cold gas is passes to the individual frame compartment
via separate cooling gas ducts. From these frames compartment the gas then flow into

[23]

the air gap through slots and the core where it absorbs the heat from the core. To
dissipate the higher losses in core ends the cooling gas section. To ensure effective
cooling these ventilating ducts are supplied from end winding space.
Another flow path is directed from the stator end winding space paste the clamping
fingers between the pressure plate and core section into the air gap along either side of
flux shield. All the flows mix in the air gap and cool the rotor body and stator bore
surfaces. The air gap is then returned to the coolers via the axial flow fan. To ensure
that the cold gas directed to the exciter end cannot be directly discharged into the air
gap. An air gap choke is arranged with in the stator end winding cover and the rotor
retaining rings at the exciter end.

Primary Cooling Water Circuit in the Generators:

The treated water used for cooling of the stator winding, phase connectors and
bushings is designated as primary water in order to distinguish it from the secondary
coolant (raw water, compensator etc.). The primary water is circulated in a closed
circuit and dissipates the absorbed heat to the secondary cooling in the primary water
cooler. The pump is supplied with in primary water cooler. The pump is supplied with
in the primary water tank and delivers the water to the generator via the following
flow paths:
Flow path I:
Flow path I cools the stator winding. This flow path passes through water manifold on
the exciter end of the generator and from there to the stator bars via insulated bar is
connected to the manifold by a separate hose. Inside the bars the cooling water flows
through hollow strands. At the turbine end, the water is passed through the similar
hoses to another water manifold and then return to the primary water tank. Since a
single pass water flow through the stator is used, only a minimum temperature rise is
obtained for both the coolant and the bars. Relatively movements due to the different
thermal expansions between the top and the bottom bars are thus minimized.
Flow Path II:
Flow path II cools the phase connectors and the bushings. The bushing and the phase
connectors consist of the thick walled copper tubes through which the cooling water is
circulated. The six bushings and phase connectors arranged in a circle around the
stator winding are hydraulically interconnected so that three parallel flow paths are
obtained. The primary water enters three bushings and exits from the three remaining
bushings. The secondary water flow through the primary water cooler should be
controlled automatically to maintain a uniform generator temperature level for various
loads and cold-water temperatures.

[24]

EXCITATION SYSTEM

In large synchronous machines, the field winding is always provided on the rotor,
because it has certain advantages they are:

It is economical to have armature winding on the stator and field winding on the
rotor.
Stationary armature windings can be insulated satisfactorily for higher voltages,
allowing the construction of high voltage synchronous machines.
Stationary armature winding can be cooled more efficiently.
Low power field winding on the rotor gives a lighter rotor and therefore low
centrifugal forces. In view of this, higher rotor speeds are permissible, thus
increasing the synchronous machine output for given dimensions.

[25]

Design features
The excitation system has a revolving field with permanent magnet poles. The threephase ac output of this exciter is fed to the field of the main exciter via a stationary
regulator & rectifier unit.
Three-phase ac induced in the rotor of the main exciter is rectified by the rotating
Rectifier Bridge & supplied to the field winding of the generator rotor through the dc
lead in the rotor shaft. A common shaft carries the rectifier wheels, the rotor of the
main exciter & PMG rotor. The shaft is rigidly coupled to the generator rotor. The
generator & exciter rotors are supported on total three bearings.

Three Phase Pilot Exciter

It is a six-pole revolving field unit. The frame accommodates the laminated core with
the three-phase winding. Each pole consists of separate permanent magnets that are
housed in a non-magnetic metallic enclosure.

Three Phase main exciter

The three phase main exciter is a six-pole armature-revolving unit. The field winding
is arranged on the laminated magnetic poles. At the pole shoe, bars are provided
which are connected to form a damper winding.
Between the two poles, a quadrature-axis coil is provided for inductive measurement
of the field current. After completing the winding & insulation etc., the complete rotor
is shrunk on the shaft.

Rectifier wheel
The silicon diode is the main component of the rectifier wheels, which are arranged in
a three-phase bridge circuit. With each diode, a fuse is provided which serves to cut
off the diode from the circuit if it fails. For suppression of the momentary voltage
peaks arising from commutation, R-C blocks are provided in each bridge in parallel
with each set of diodes.
The rings, which form the positive & negative side of the bridge, are insulated from
the rectifier wheel which in turn is shrunk on the shaft. The three phase connections
between armature & diodes are obtained via copper conductors arranged on the shaft
circumference between the rectifier wheels &the main exciter armature.

[26]

Voltage regulator
The voltage regulator is intended for the excitation and control of generators equipped
with alternator exciters employing rotating uncontrolled rectifiers. The main parts of
the regulator equipment are two closed-loop control systems including a separate gate
control set and Thyristor set each, field discharge circuit, an open loop control system
for exchanging signal between the regulator equipment and the control room, and the
power supply circuits.

Voltage regulation
The active and reactive power ranges of the generator have required a wide excitation
setting range. The voltage regulator in the restricted sense, i.e. the control amplifiers
for the generator voltage controls via the gate control set the Thyristor so as they
provide quick correction of the generator voltage on changing generator load. For this
purpose the gate control set changes the firing angle of the Thyristor as a function of
the output voltage of the voltage regulator. The main quantities acting on the input of
the voltage regulator are the set point and the actual value of the generator voltage.
The set point is divided into a basic set point (e.g. 90% rated voltage) and an
additional value (e.g. 0 to 20%), which can be adjusted from the control room. In this
case the setting range is 90 to 110%. With operation at the respective limits of the
capability curve, further, influencing variable are supplied by the under and over
excitation limiters.
To partly compensate the voltage drop at the unit transformer, a signal proportional to
the reactive current can be added to the input, the controlled voltage level then rising
together with the reactive current (overexcited) thereby increasing the generator
degree of activity in compensating system voltage functions. Further, signals can be
added if necessary via free inputs.

BRUSHLESS EXCITOR STATOR

The various schemes, for supplying D.C. excitation to the field winding to large turbo
generators are given below:

The Pilot Exciter and the main exciter are driven by the turbo generators main
shaft. The pilot Exciter, which is a small D.C. shunt generator, feeds the field
winding of main exciter is given to the field winding of the main alternator, through
slip-rings and brushes. The function of the regulator is to keep the alternator
terminal voltage constant at a particular value.
In this second scheme it consists of main A.C. exciter and stationary solid-state
rectifier. The A.C. main exciter, which is coupled to shaft of generator, has rotating

[27]

field and stationary armature. The armature output from the A.C. exciter has a
frequency of about 400 Hz. This output is given to the stationary solid-state
controlled rectifier. After rectification, the power is fed to the main generator field,
through slip rings and brushes.
In third scheme the A.0 exciter, coupled to the shaft that drives the main generator,
has stationary field and rotating 3-phase armature. The 3-phase power from the A.0
exciter is fed, along the main shaft, to the rotating silicon-diode rectifiers mounted
on the same shaft. The output from these rectifiers is also given, along the main
shaft, to the man generator field, without any slip rings and brushes. In the other
words, the power flows along the wires mounted on the main shaft, from the A.C.
exciter to the silicon diode rectifiers and then to the main generator field. Since the
scheme does not require any sliding contacts and brushes, this arrangement of
exciting the turbo generators has come to be called as Brush less Excitation system.

For large turbo generators of 500 MW excitation systems, the direct cooling required
by the rotating field winding increases considerably (up to 10 kA or so). In such cases,
the brush gear design becomes more complicated and reliability of turbo generator
operation decreases. The only promising solution of feeding the field winding of large
turbo generator is the brush less excitation system. In view of its many advantages, the
brush less excitation system is employed in almost all large turbo generators being
designed and manufactured now days. Here are some merits of Brush less Exciters.

Eliminates slip rings, brush gear, field breaker and excitation bus/cables.
Eliminates all the problems associated with transfer of current via sliding contacts.
Simple, reliable and ideally suited for large sets.
Minimum operation and maintenance cost.
Self-generating excitation unaffected by system faults or disturbances of shaft
mounted pilot exciter.

ELECTRICAL GENERATOR PROTECTIONGenerator may be endangered by short circuit, ground fault, over voltage, under
excitation and excessive thermal stresses. The following protective equipment is
recommended
1) Differential protection
2) Stator ground fault protection
3) Rotor ground fault protection
4) Under excitation protection
5) Over current protection

[28]

6) Load unbalance protection

7) Rise in voltage protection
8) Under-frequency protection
9) Reverse power protection
10)Over voltage protection

SALIENT DESIGN FEATURES

1) Air Cooled Turbo Generators Up To 200 MW Range (Type. - TARI)

Stator core and rotor winding direct air cooled

Indirect cooling of stator winding

Horizontally split casing design of stator

Vertically side mounted coolers in a separate housing

Moralistic bar type insulation system

Separately assembled stator core and winding for reducing the manufacturing
cycle

Brush less/static excitation system

2) Hydrogen & Water-Cooled Turbo Generators Of 200-235 MW range

(Type: THW)

Stator winding directly water cooled

Rotor winding directly hydrogen cooled by gap pick up method

Resiliently mounted stator core on flexible core bars

Thermo reactive resin rich insulation for stator winding

Top ripple springs in stator slots

Enclosed type slip rings with forced ventilation

Ring/thrust type shaft seal

Two axial fans for systematic ventilation and four hydrogen coolers

Static excitation

[29]

3) Hydrogen Cooled Turbo Generators Of 140-260 MW range (Type: THRI)

Stator core and winding directly hydrogen cooled

Indirect cooling of stator winding

Rigid core bar mounting

Micalastic insulation system

End shield mounted bearings

Top ripple springs in stator slots

Ring type shaft seals

Symmetrical ventilation

Brush less/ static excitation

Integral coupling of rotor

4) Hydrogen & Water-Cooled Turbo Generators of 500 MW range (Type:

THW)

Stator winding directly water-cooled

Rotor winding direct hydrogen cooled (axial)

Leaf spring suspension of stator core

Micalastic insulation system

End shield mounted bearings

Support ring for stator over hang

Magnetic shunt to trap end leakage flux

Ring type shaft seals with double flow

Multistage compressor and vertical coolers on turbine end

Brush less/static excitation

Integral coupling of rotor

[30]

STATOR BAR MANUFACTURING AT CIM (BLOCK-4)

This Block manufactures stator bars for all types of TGs [i.e., 210MW, 500MW,
600MW, 800MW] the steps involving in the process of stator bar manufacturing
are as follows:
- Conductor Draw from Store.
- Conductor cutting and end cleaning.
- Transposition of conductor.
- Assembly of all conductors to be used in stator Bars.
- Cross over insulation.
- Consolidation if slot portion of Bar.
- I.S. Test (i.e. inter strand test).
- Forming or Bar (to shape overhang portion).
- Pickling of bar ends (1)
- Mounting of Contact sleeve & bottom part of water box.
- Brazing of Contact sleeve & bottom part of water box.
- Pickling of bar ends (2)
- Mounting of water box leak test.
- Re-pickling.
- Water flow and N2 test.
- Thermal Shock Application.
- Helium Leak Test.
- Reforming of Bar.
- Insulation of bar on CNC machine.
- Impregnation a curing of bar insulation.
- Surface finishing of stator bar.
- OCP on stator Bar.
- Preparation of bar for HV and Tan Test.

1. Conductor cutting:
This process is done by automatic CNC machine. In this process the pre-insulated
copper conductor is cut into number of pieces of required length (length given in
drawing as per design) insulation is removed from both ends of the copper
conductor out.

[31]

2. Transposition:
Transposition means changing/shifting of position of each conductor in active
core (slot) part. After cutting the required number of conductors, 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.

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 (insulating putty of
molding micanite) 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.

6. Forming
The straight bar stack is formed 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.

[32]

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.

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

[33]

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.
Insulation Classification:
Thermal classification of insulation depends upon the temperature withstand
capacity of the insulation.
Class- Y up to 90C
Class- A up to 105C
Class- E up to 120C
Class- B up to 130C
Class- F upto150C
Class- H up to 180C
Class- C > 180C and up to 220C

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:
(a)Tan Test: This test is carried out to ensure the healthiness of dielectric
Insulation) i.e. dense or rare and measured 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.
Set type

210 MW
250 MW
500 MW
600 MW
Exciter

Conductor
Length(mm)
[Upper/lower]
7000/7300
8200
10050/10200
10887/11053
1680/1620

No.
of
conductors
[solid/hollow]
28/14
80
20/10 & 10/10
28/14
144

[34]

Transposition
Transposition means changing/shifting of position of each conductor in active core
(slot) part. After cutting the required number of conductors, 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.
Why Transposition is required?
1. Equalize the voltage generator.
2. To minimize skin effect of ac current so small cross section of conductor is used
and also hollow conductors are used for effective cooling by D.M. water.
3. To reduce the eddy current loses.

Degreasing and Pickling Process

- Degreasing : Trichloroethylene
- Cleaning of Insulation (at ends due to formation of oxides): Sulphuric Acid
- Cleaning by Water: Flowing water
- Pickling : Pickling Solution at 45C
- Cleaning by Water : Take out Cu bars 3 Times in 1 minute
- Neutralizing: Neutralizing Solution. Dip 3 minutes
- Cleaning by Water : Flowing Water
- Cleaning by Spirit .

[35]

ROTOR BAR MANUFACTURING AT ACM (BLOCK-4)

Following Steps are involved in manufacturing of Rotor Bars depending upon the
capacity of the generator.

Bars for 250MW Rotor

- Slot Punching
- Scraping
- 1st Annealing
- Edge Bending
- Pressing
- 2nd Annealing
- Radius Bending
- Moulding
- Finishing

Bars for 500MW Rotor

- Drilling
- Centre Champhering + Internal Debarring
- Cocking (Small and Large Filling)
- 1st Annealing
- Edge wise Bending
- Pressing
- 2nd Annealing
- Radius Bending
- Moulding
- Finishing

Bars for 600MW Rotor

Same as 500MW but here, but,
- No filler, so no brazing, so no annealing
- Also, this category of bars has a full arc on side of the coil unlike 500MW where
both coil sides have of the arc.

Significance of Important Processes:

1. Slot Punching: In THRI, the cooling of Rotor is Radial type where the blades on the
rotor force H2 to pass through the slots and cool the rotor. For this reason, slots are
inevitable as they increase the surface area of cooling of rotor bars.

[36]

2. Annealing: Every metal responds to thermal shocks in different way. Copper when
molded by hammering, develops cracks due to brittleness. So, annealing cures this.
3. Radius Bending: This is the most important part of the process. The arc required to
make a full concentric coil is done through this process on a mold by hammering
manually. The arc is full in case of 600 MW and half in case of 500MW. There are 7
types of Rotor bars depending upon the arc. They are numbered here from A through
G. A has the least arc while G has the largest arc. They are arranged in concentric
manner to generate a concentrated field through rotors physical poles.

Types of Rotor Bar as per Cooling Method Employed:

1. Solid Rotor Bars.
For THRI (Generators with generating capacity of <250 MW) have solid rotor bars
with slots punched through them.

2. Hollow Rotor Bars

For THDF (LST Generators with generating capacity of >250 MW like 500MW and
600MW) have hollow rotors through which H2 enters through one end and leaves at
the middle of the bars through holes provided for the same.

Resin system:
(a) Rich resin or Thermo reactive insulation system: In this type of insulation
system the bond content in resin is 35-37%. The raw materials are ready to use and
require preservation and working on temperature 20-25C. its shelf life is one year
when kept at temperature 20C which could be increased when kept at temperature of
5C
(b) Poor resin or Micalastic insulation system: In this type of insulation the bond
content in the resin is 5-7% and insulation material is prepared with accelerator
treatment. The temperature control need not required. The insulating material is
applied on job and then the same is impregnated in the resin.

[37]

CONCLUSION
The training at BHEL-Haridwar provided me the knowledge on manufacturing
of Turbo Generator sets. The staff and the engineers here were very cooperative and I thank them for sharing their knowledge and experience with us.

[38]