A PROJECT REPORT ON TURBO GENERATORS B.H.E.L. HARIDWAR .

RANIPUR , HARIDWAR

SUBMITTED BY GOPAL DIXIT B. Tech. 3rd year (EE) I. E. T. Lucknow

ACKNOWLEDGEMENT

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An engineer with only theoretical knowledge is not a complete engineer. Practical knowledge is very important to develop and apply engineering skills. It gives me a great pleasure to have an opportunity to acknowledge and to express gratitude to those who were associated with me during my training at BHEL, Haridwar. My sincere thanks goes to Mr. P.S. JANGPANGI (S.D.G.M.) for his well guidance. Special thanks goes to Mr. NEERAJ KUMAR SINGH (Sr. Engineer) who helped me a lot in giving minute details of the va rious technical aspects of machine design. I express my sincere thanks and gratitude to BHEL authorities for allowing me to undergo the training in this prestigious organization. I will always remain indebted to them for their constant interest and excellent guidance in my training work, more over for providing me with an opportunity to work and gain experience. GOPAL DIXIT B. Tech. 4TH YEAR (EE) I.E.T. Lucknow

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INDEX TOPIC

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B.H.E.L. An Overview Electrical Machines Block(Block-1) Manufacturing process of Turbo Generators Introduction to 500MW Turbo Generators Constructional Features of Stator Body Constructional Features of Stator Core Constructional Features of Stator Winding Constructional Features of Rotor Cooling System Excitation System Electrical Generator Protection Conclusion Bibliography

BHEL: AN OVERVIEW

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Bharat Heavy Electricals Ltd has emerged as the largest engineering and manufacturing enterprise of its own kind in India with an excellent track record of performance The Company is engaged in engineering, development and manufacturing of a wide variety of electrical and mechanical equipment for generation, transmission and utilization of energy and electrical power . The company today enjoys national and international presence featuring in the "Fortune International 500" and is ranked among the top 10 companies in the world manufacturing power generation equipment. BHEL has now thirteen manufacturing divisions, eight service centers and four power sector regional centers, besides a large number of projects sites spread all over India and abroad. This enables prompt service to the customers with state-of-art products, systems and services that meet the needs of energy, industry, transportation and other key sectors.

HEAVY ELECTRICAL EQUIPMENT PLANTBHEL's Heavy Electrical Equipment Plant (HEEP) was set up in technical collaboration with USSR, for the manufacturing of power plant equipment, AC/DC motors of various with associated control equipment and started production in January 1967. In 1976, BHEL entered into a

collaboration agreement with M/s Kraft work Union. BHEL is the largest engineering and manufacturing enterprise on India in the energy related/infrastructure sector. BHEL has attained ISO 9001:2000 certifications for quality management and all the manufacturing units divisions of BHEL have been upgraded to the latest ISO 9001:2000version. More than 40 percent of the country's electrical energy is generated from the power equipment supplied by BHEL. It has also won the Business standard star Public Sector Company Award 2006. manufacturing. It has been earning profits continuously since 1971-72. ushering in the indigenous Heavy Electrical Equipment industry in India. BHEL was established more than 40 years ago. Haridwar. a dream which has been more than released with a well-recognized track record of performance. erection and commissioning of large size steam turbines. BHEL is the only PSU among the 12 Indian Companies to figure in Forbes Asia Fabulous 50 list. AG of Germany for design.The . BHEL become the first public sector Company in the country to win the coveted prize for in Haridwar unit under the CII Exim Award for the business excellence as per the globally recognized model of European Foundation for quality management. All the major units divisions of BHEL have been awarded ISO 14001 certification for Environmental Management System and OHSAS-18001 certification for Occupational Health and Safety management System.

oil and gas. petrochemicals. Power Generation Power generation Sector comprises Thermal Gas. To make efficient use of the high-ash-content coal available in India.company received MoU Excellence award for 2004-2005 and Merit Certificate for MoU Excellence for 2005-2006. BHEL supplied sets accounts for 80.3. As of 31. Cogenerating and combined cycle plants have been introduced to achieve higher plant efficiencies. BHEL also supplies circulating Fluidized Bed Combustion (CFBC) boilers for thermal plants.781 MW or nearly 65% of the total install capacity of 1. co-generation . sugar. Hydrogen. Nuclear power plant business. fertilizer. It possesses the technology and capability to produce Thermal sets with super critical parameters up to 1000 MW unit rating and gas turbine generator sets of up to300 MW units rating. refineries. The range of systems &equipment supplied includes: captive power plants. BHEL has proven turnkey capabilities for executing power projects from concepts to commissioning. Significantly these sets contribute 73% of the total power generated in the country.414 MW in the country. INDUSTRIES BHEL is a major contribution of equipment and systems to industries: cement.2007. paper. metallurgical and other process industries. 25.

Technology Up gradation. industrial boilers and auxiliaries. electrostatic precipitators. fluidized bed combustion boilers. The company has upgraded its products to contemporary levels through continuous in house efforts as well as through acquisition of new technologies from leading engineering organizations of the world. process controls and material handling systems. The company has commenced manufacture of large desalination plants to help augment the supply of drinking water to people. BHELs investment in R&D is amongst the largest in the corporate sector in India. Research & Development: To remain competitive and meet customer expectations. defense and other applications. Italso supplies digital distributed control systems for process industries and control & instrumentation systems for power plant and industrial application. waste heat recovery boilers. valves . and development of new products. Products developed in-house during the last five years . centrifugal compressors. he company is a major producer of large ± size thruster devices. pumps. DG power plants industrial steam turbines. BHEL is the only company in INDIA with the capability to make simulators for power plants. gas turbine. electrical machine. fabric filters. BHEL lays great emphasis on the continuous up gradation of products and related technologies.seamless steel tubes. reactors.plants. heat exchangers and pressure vessels.

36 kv gas insulated sub stations.contributed over 7% to the revenues in 2002-03 BHEL has introduced. controlled shunt Reactors (CSR) and Performance Analysis. Diagnostics and optimization(ADO) package for power plants etc. petroleum depot automation systems. . such as application of super conducting materials in power generation and industry and fuel dells for distributed environment-friendly power generation. in the recent past. The company is also engaged in research in futuristic areas.. high efficiency pelt on hydro turbines. several stage of the art products: Low Nix oil/gas burners. The company has also transferred a few technologies developed in house to other Indian companies for commercialization . large capacity atmospheric fluidized bed combustion boilers.

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

Stampings are received from stampings manufacture block. VI. VIII). bars.MANUFACTURING PROCESS . The boring and facing of stators are done on CNC horizontal boring machine using a rotary table.Turbo Generators a) Making of blanks is done for checking the availability of machining allowances.II and other small components in Bay . The centering . while castings and forgings are received from sister unit CFFP and other indigenous and foreign sources for Turbo Generators . V.I & Bay.III and Bay IV. insulating details and sheet metal components are received from coils and insulation manufacture and apparatus and control gear box (block IV) 1. c) In case of large size Turbo Generators core bars are welded to stator frame with the help of telescopic centering device. b) Machining of the major components is carried out in Bay . The shaft is turned on lathe having swift 2500 mm and the rotor slots are milled on a special rotor slot milling machines. block²VI and coils. Fabricated components are received in respective machine sections from Fabrication blocks (Block ² II.

After laying of lower and upper bars. with the help of ferrule and then soldered by resistance soldering. Punching are assembled manually and cores are heated and pressed in number of stages depending on the core length.of core bar is done very precisely. The pressing of overhang portion is carried out on special ring type hydraulic press. d) Stator winding is done by placing stator on rotating installation. The dynamic balancing of rotors is carried out on the over speed balancing installation. e) Rotor winding assembly is carried out on special installation where coils are assembled in rotor slots. g) Turbo Generators are tested as per standard practices and customer requirements. these are connected at the ends. whereas slot portion is pressed manually with the help of rotor wedges. . Rotor is inserted in the stator and assembly of end shields. Coils are wedged with special press after laying and curing. 500 MW Turbo Generators are balanced in vacuum balancing tunnel f) General assembly of Turbo Generators is done in the test bed. bearings etc are carried out to make generators ready for testing Prior to test run the complete generator is hydraulically tested for leakages.

85 Lag 98.TURBO GENERATOR 500MW Turbo generators at a glance2-Pole machine with the following features:y Direct cooling of stator winding with water y Direct hydrogen cooling for rotor y Mica elastic insulation system . 500 MW 21 KV 16 KA 50 Hz 0.83Mx4.lMx4. y Spring mounted core housing for effective transmission of vibrations y Brushless Excitation system y Vertical hydrogen coolers Salient technical data- Rated output Terminal voltage Rated stator current Rated frequency Rated power factor Efficiency : : : : : : 588 MVA .55% Important dimensions & weights- Heaviest lift of generator stator Rotor weight : 255 Tons : 68 Tons Overall stator dimensions [Lx Bx H] : 8.02M .

6 KV.8 MW.how in record time for testing Turbo generators of ratings 500 MW and above up to 1000 MW. 3000 RPM AC non salient pole. rotor slot milling machine etc. have been specially developed by BHEL y 12 MW/10. 6.11 M : 428 Tons Unique installationsHeavy Electrical Equipment Plant. It caters to the most advanced requirement of testing by employing on-line computer for data-analysis. 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 Bed New LSTG [Large Scale Turbo Generator] Test Bed has been put up with indigenous know. thermal shocks test equipment. Other major facilities are as follows y Major facilities like stator core pit equipped with telescopic hydraulic lift. synchronous motor has been used for driving the 500 MW Turbo-generator at the . micalastic plant for the manufacture of stator bars.15M dia x 12.Rotor dimensions length Total weight of turbo generator : 1.

Generator transportation y Transport through 300 Tons 24-Axle carrier beam railway wagon specially designed indigenously and manufactured at Haridwar y The wagon has been used successfully for transporting one generator -from Calcutta Port to Singrauli STPP.pole (3000 rpm) Over speed Balancing vacuum tunnel For balancing and over speeding large flexible Turbo generators rotors in vacuum for ratings up to 1. testing at operational speed and for over speeding . .000 MW.TEST Bed The motor has special features to suit the requirement of TG testing (500 MW and above) This is the largest 2. 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.

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For filling the generator with . These stainless steel pipes serve as inlet and outlet for gas coolers. Pipe Connection To attain a good aesthetic look. the water connection to gas cooler is done by routing stainless steel pipes. It is suitably ribbed with annular rings in inner walls to ensure high rigidity and strength.CONSTRUCTIONAL FEATURES OF STATOR BODY Stator frame . Stator body is a totally enclosed gas tight fabricated structure made up of high quality mild steel and austenitic steel. From sidewall these are connected to gas coolers by the means of eight U-tubes outside the stator body. which emanates from bottom and emerges out of the sidewalls. inside the stator body. The natural frequency of the stator body is well away from any of exiting frequencies. 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. Inner and sidewalls are suitably blanked to house for longitudinal hydrogen gas coolers inside the stator body.

This material eliminates stray lossesdue to eddy currents. which may results in excessive heating. 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. a perforated manifold is provided at the top inside the stator body. 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 terminal brushing in the terminal box. The terminal box is a welded construction of (non magnetic) austenitic steel plates .hydrogen. Testing of Stator Body On completion of manufacture of stator body. . 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 .

Segments are assembled in an interleaved manner from layer to layer for uniform permeability.Insulating paper pressboards are also put between the layer of stamping to provide additional insulation and to localize short circuit. Segments are stamped out with accurately finished die from the sheets of cold rolled high quality silicon steel. It consists of thin laminations .Constructional Feature of stator Core Core . Core is stacked with lamination segments. Between two packets one layer of ventilating segments is provided .The pressed core is held . Before insulation on with varnish each segment is carefully debarred. Stampings are hydraulically compressed during the stacking procedure at different stages.Each lamination made of number of individual segments.Steel spacers are spot welded on stamping. Stampings are held in a position by 20 core bars having dovetail section . These spacers from ventilating ducts where the cold hydrogen fromgas coolers enter the core radially inwards there by taking away theheat generated due to eddy current losses .

To monitor the formation of hot spots resistance transducer are placed along the bottom of slots.Twenty core bars are welded to inner walls of stator body with help of brackets . Core Suspension The elastic suspension of core consist of longitudinal bar type spring called core bars . The core bars are designed to maintain the movement of stator core with in satisfactory limits. 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.To avoid-heating of press ring due to end leakage flow two rings made of copper sheet are used on flux shield . 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 . Thus offering a hold point for stamping core bars have longitudinal slits which acts as inertial slots and help in damping the vibration . The ring screens the flux by short-circuiting .These are made up of spring steel having a rectangular cross section and dove-tail cut at tap.The press ring is bolted to the ends of core bars. .in pressed condition by means of two massive non-magnetic steel castings of press ring . similar type of dove-tail is also stamped on to stamping and fit into that of core bar dove-tail .

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.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 . To ensure that strands are firmly bonded together and give dimensionally stability in slot portion.Alternate arrangement hollow and solid conductors ensure an optimum solution for increasing current and to reduce losses . Each slots accommodated two bars.CONSTRUCTIONAL FEATURES OF STATOR WINDING .The current flowing through the conductor is uniformly distributed over the entire bar cross section reduced. short pitched and bar type of windings having two parallel paths. double layer. General The stator has a three phase. Conductor Construction Each bar consist of solid as well as hollow conductor with cooling water passing through the latter . a layer of glass tape is wrapped .

. (b)Each bar is subjected to hydraulic test to ensure the strength of all joints.This insulation shows only a small increase in dielectric dissipation factor with increasing test voltage .This type of insulation is more reliable for high voltage .The voltage of machine determines the thickness of insulation . This is applied continuously and half overlapped to the slot portion .Bar insulation is done with epoxy mica thermosetting insulation . Method Of Insulation Bar is tapped with several layers of thermosetting epoxy tape.The tapped bar is then pressed and cured in electrical heated press mould for certain fixed temperature and time.The various test for manufacture the bar are performed which are as follows: (a)Inter turn insulation test on stuck after consolidation to ensure absence of inter short.The bar insulation is cured in an electrically heated process and thus epoxy resin fill all voids and eliminate air inclusions.over the complete stack . Corona Prevention To prevent corona discharges between insulation and wall of slots.This insulation is void free and posses better mechanical properties . the insulation in slot portion is coated with semiconductor varnish .

In between top and bottom bars. (f) Dielectric loss factor measurement to establish void free insulation. spacers are also put.(c)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 .Driving in semi conducting filler strips compensates any manufacturing tolerances. Any gaps due to design or manufacturing considerations are fitted with curable prepag with spacer in between . Ending Winding In the end winding. Lower and upper layers are fixed with epoxy glass ring made in segment and flexible spacer put in between two layers. which are uniformly distributed on the circumference . slot wedges are inserted .A semiconducting spacer is placed in bottom of slots to avoid any damage to bar due to any projection . .Below slots wedges high strength glass texolite spacers are put to have proper tightness. Laying of Stator Winding The stator winding is placed in open rectangular slots of the stator core. (e) High voltage to prove soundness of insulation.The prepag material is also placed between the brackets and binding rings. After laying top bar. the bars are arranged close to each other . (d)Leakage test by means of air pressure is performed to ensure gas tightness of all joint.

These bus bars are connected with terminal bushing. . Both are water-cooled Brazing the two lugs properly makes connection. Bus bars are also hollow from inside.Bus bars are connected to bring out the three phases and six neutrals.

The rotor shaft is a long forging measuring more than 9m in length and slightly more than one meter in diameter.The shaft and body are forged integral to each other by drop forging process. Approximately 60 % of the rotor body circumference is with longitudinal slots. vacuum casting. nickel and vanadium . The main constituents of the steel are chromium. which hold the field winding.CONSTRUCTIONAL FEATURES OF ROTOR The rotor comprises of following component: 1) Rotor shaft 2) Rotor winding 3) Rotor wedges and other locating parts for winding 4) Retaining ring 5) Fans 6) Field lead connections 1) Rotor Shaft The rotor shaft is a single piece solid forging manufactured from a . molybdenum. Following tests are done:(a) Mechanical test (b) Chemical analysis (c) Magnetic permeability test (d) Micro structure analysis (e) Ultrasonic examination (f) Boroscope examination .

For high accuracy the rotor is subjected to 20% over speeding for two minutes. .Further these half turns are brazed in series to form coil on the rotor model. longitudinal slots are milled on sophisticated horizontal slot milling machine. The solid poles are provided with additional slots in short lengths of two different configuration. The slot house the field winding consists of several coils inserted into the longitudinal slots of rotor body. Rotor Winding After preliminary turning.The slot pitch is selected in such a way that two solid poles displaced by 180oC are obtained.The rectangular cross section copper conductors have ventilating ducts on the two sides thus providing a channel for hydrogen flow.On 2/3 of its circumference approximately the rotor body is provided with longitudinal slot to accommodate field winding . Copper Conductor The conductors are made of hard drawn silver bearing copper . Two individual conductors placed-one over the other are bent to obtain half turns . 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.

The coils are .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 .

In this cooling method the temperature rise becomes independent of length of rotor . At the bottom of slot D-shaped liners are put to provide a plane seating surfaces for conductors and to facilitate easy flow of gas from one side to another .The overhang portion of the winding is cooled by axial two systems and sectionalized into small parallel paths to minimize temperature rise.The overhang winding are insulated from retaining rings segments having Lshape and made of glass cloth impregnated by epoxy resin. The overhang winding is separated by glass laminated blocks called liners . .These liners are made from molding material.The gas then passes into the corresponding ducts on the other side and flows outwards and thrown into the gap in outlet zones.insulated from rotor body by U-shaped glass laminate module slot through made from glass cloth impregnated with epoxy varnish. Cooling of winding The rotor winding are cooled by means of direct cooling method of gap pick-up method . Cold gas enters the overhang from under the retaining rings through special chamber in the end shield sand ducts under the fan hub and gets released into the air gap at rotor barrel ends.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 .

Rotor wedges For protection against the effect of centrifugal force the winding is secured in the slots by slot wedge .resulting in high mechanical strength. securing. austenitic steel and cold worked. Retaining Ring The overhang portion of field winding is held by non-magnetic steel forging of retaining ring against centrifugal forces . the retaining. rings are made of nonmagnetic. The wedges at the ends of slot are made from an alloy of chromium and copper . magnesium and aluminum having high good electrical conductivityand high mechanical strength. .The wedges are made from duralumin. The centering rings are shrink fitted at the free end of retaining ring that serves to reinforce the retaining ring.They are shrink fitted to end of the rotor body barrel at one end.These are connected with damper segments under the retaining ring for short circuit induced shaft current . while at the other side of the retaining ring does not make contact with the shaft.Ventilation slot wedges are used to cover the ventilation canals in the rotor so that hydrogen for overhang portion flows in a closed channel. end winding in axial direction at the same time . an alloy of copper.To reduce stray losses.

A field lead bar. does the connection between current carrying bolt and field winding that of semi flexible . are machined in the tail portion so that they fit into the groove of the fan hub. Fans hubs are made of alloy steel forging with three peripheral grooves milled on it.The radial holes with current carrying bolts in the rotor shafts are effectively sealed to prevent the escape of hydrogen. 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 fans are shrink fitted on either sides of rotor body. 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. which are precision casting with special alloy. Field Lead The slip rings are connected to the field winding through semi flexible copper leads and current-carrying bolts placed in the shaft . Fan blades. which has similar construction as.Fans Two single stage axial flow propeller type fans circulate the generator cooling gas.

copper leads (they are insulated by glass cloth. . impregnated with epoxy resin for low resistance and ease of assembly).

. insulation . particularly to the copper conductors. 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. Heat losses arising in generator interior are dissipated to secondary coolant (raw water.Direct cooling essentially eliminates hot spots and differential temperature between adjacent components.) through hydrogen and Primary water . Flow path II Flow path II is directed from the cooler to the individual frame compartments for cooling of the stator core. which could result in mechanical stresses.COOLING SYSTEM . rotor body and stator core. Hot gases is drawn by the fan from the air gap and delivered to the coolers where it is recooled 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 . condensate etc.

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 . The hydrogen flows through each individual conductor is closed cooling ducts.Cold gas is directed to each cooling zone through separate openings directly before the rotor body end.The rotor winding is symmetrical relative to generator centerline and pole axis .The gas is then returned to the coolers via the axial flow fan. 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 . 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 three flow paths miss the air gaps . 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. The heat removing capacity is selected such that approximately identical temperature is obtained for all conductors.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.

rotor body.The primary .).An air gap choke is arranged with in the stator end winding cover and the rotor retaining rings at the exciter end. From these frames compartment the gas then flow into the air gap through slots and the core where it absorbs the heat from the core. cold gas is passes to the individual frame compartment via separate cooling gas ducts. 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. condensator etc. The air gap is then returned to the coolers via the axial flow fan. Primary Cooling Water Circuit In The Generators The treated water used for cooling of the stator winding. phase connect or sand bushings is designated as primary water in order to distinguish it from the secondary coolant (raw water. These ventilating ducts are supplied from end winding space.To ensure effective cooling. To ensure that the cold gas directed to the exciter end cannot be directly discharged into the air gap. 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. To dissipate the higher losses in core ends the cooling gas section .

At the turbine end.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. .The pump is supplied with in primary water cooler .water is circulated in a closed circuit and dissipates the absorbed heat to the secondary cooling in the primary water cooler . the water is passed through the similar hoses to another water flows through hollow strands.The pump is supplied with in the primary water tank and delivers the water to the generator via the following flow paths. Inside the bars the cooling water flows through hollow strands . Flow The path II cools the phase connectors and the bushings the phase connectors consist of the thick walled copper tubes through which 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. Flow Path II Bushing and the cooling water is circulated. Flow path I Flow path I cools the stator winding .

the control amplifiers for the generator voltage controls via the gate control set the thyristors .the generator and exiter are connected to the total three bearings. The voltage regulator in the restricted sense. In large synchronous machines. It has the following main parts : y Three phase pilot exiter .EXCITATION SYSTEM: . the field winding is always provided onthe rotor. y Rectifier wheel y RC filter y Voltage regulator The active and reactive power ranges of the generator require a wide. the rotor of the main exciter and PMG rotor . Design features shaft A common carries the rectifier wheels. because it has certain advantages they are y It is economical to have armature winding on the stator and fieldwinding on the rotor y Stationary armature windings can be insulated satisfactorily for higher voltages. . the shaft is rigidly connected to generator rotor . y Three phase main exiter . allowing the construction of high voltage synchronous machine.

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over voltage. ground fault.ELECTRICAL GENERATOR PROTECTION . Generator may be endangered by short circuit. protective equipment is recommended: 1) The following Differential protection 2) Stator ground fault protection 3) Rotor ground fault protection 4) Under excitation protection 5) Over current protection 6) Load unbalance protection 7) Rise in voltage protection 8) Under-frequency protection 9) Reverse power protection 10) Over voltage protection . under excitation and excessive thermal stresses.

However training has proved to be satisfactory but it has allowed us an opportunity to get an exposure of the practical implementation of theoretical knowledge. .It provides an opportunity to learn technology. used at proper places can save labour and time.CONCLUSION The architechture of BHEL the way various units are linked and the way the whole plant working make the engineers realize that the engineering is not merely a structural description but greater part is the planning and management . .

Bimbhra) y Electrical Machine Design (A.BIBILOGRAPHY y BHEL Turbo generator manual y Electrical Machinary (Dr. sawheny) y BHEL Product information provided at : http://www.com .bhel.S. K. . P.

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