BHEL HARIDWAR VOCATIONAL TRAINING REPORT

BHARAT HEAVY ELECTRICAL S LIMITED

RANIPUR ,HARIDWAR
(UTTARAKHAND )

Submitted By :
Khemraj Bairwa
2010UEE232
MNIT ,JAIPUR (RAJ.)

ACKNOWLEDGEMENT
An engineer with only theoretical knowledge is not a
complete engineer. Practical knowledge is very important to
develop and to 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.

Special thanks to Mr. Tariq Husan for providing me with an

opportunity to undergo training under his able guidance.

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,
moreover for providing me with an opportunity to work and
gain experience.

INDEX
1. INTRODUCTION
2.BHELS CONTRIBUTION IN DIFFERENT
SECTORS
3.BHEL HARIDWAR AN OVERVIEW
4.TURBO GENERATORS
a) STATOR
i) STATOR FRAME
ii)STATOR CORE
iii)STATOR WINDING
iv)

END COVERS

b)ROTOR
i) ROTOR SHAFT
ii)ROTOR WINDING
iii)ROTOR RETAINING RINGS
iv)

ROTOR FANS

c)BEARINGS
d)VENTILATION AND COOLING
e)

EXCITATION SYSTEM

f)TESTING
g)

MOTOR WINDING

5. CONCLUSION

BHEL - AN OVERVIEW

INTRODUCTION
In 1956 India took a major step towards the establishment of its heavy
engineering
industry when Bharat Heavy Electricals Limited, the first heavy
electrical manufacturing unit of the country was set up at Bhopal. It
progressed rapidly and three more factories went into production in
1956 .The aim of establishment BHEL was to meet the growing power
requirement of the country.
BHEL has supplied 97% of the power generating equipment that was
commissioned
in India during 1979-80. BHEL has supplied generating equipment to
various utilities capable of generating over 18000MW power. BHEL is one
of the largest power plant equipment manufacturing firms in India and it
ranks among the top ten manufacturers globally. BHEL has covered up
many power stations over 40 countries worldwide.
BHEL has its head quarters at New Delhi. Its operations are spread over
11 manufacturing plants and number of engineering and service
divisions located across the country. The service division includes a
network of regional offices throughout India.

BHELS UNIT IN INDIA

S.No.
1.

PLACE UNITS
HARDWAR

(PLANTS)
2

2.

BHOPAL

3.

JHANSI

4.

JAGDISHPUR

5.

HYDERABAD

6.

BANGALORE

7.

RANIPET

8.

RUDRAPUR

A BRIEF HISTORY
The first plant of what is today known as BHEL was established nearly
40 years ago at BHOPAL and was genesis of Heavy Electrical
Equipment industry in India. BHEL is today the largest engineering
enterprise of its kind in India, with a well recognized track record of
performance making profits continuously since 1971-72. It achieved a
sales turnover of Rs.1022 core in 1997-98. BHEL caters to core sectors
of the Indian Economy via, Power, Industry, Transportation, Defense,
etc.
The wide network of BHELs 14 manufacturing divisions, 9 service centers &
4 power Sector Regional centers & about 150 project sites enables the
service at competitive prices. Having attained ISO 9000 certification, BHEL
is now embarking upon the Total Quality Management. The companys
inherent potential coupled with its strong performance over the years, has
resulted in it being chosen as one of the Maharatna PSUs(on 1 February
2013 ),

which are to be supported by the Government in their endeavor to become

future global players. It is the 7th largest power equipment manufacturer in
the world. In the year 2011, it was ranked ninth most innovative company in
the world by US business magazine Forbes. BHEL is the only Indian
Engineering company on the list, which contains online retail firm Amazon at
the second position with Apple and Google at fifth and seventh positions,
respectively. It is also placed at 4th place in Forbes Asia's Fabulous 50 List of
2010

BHELS CONTRIBUTION IN DIFFERENT

SECTORS
POWER SECTOR
Power sector comprises thermal, nuclear, gas & hydro power plant
business. Today, BHEL supplied sets account for nearly 56,318 MW or
65% of the total installed capacity of 86,636 MW in as against nit till
1969-1970.
BHEL has proven turnkey capabilities for executing power projects from
concept to commissioning. It posses the technology and capability to
produce thermal power plant equipments up to 1000MW rating and gas
turbine generator sets up to a unit rating of 240 MW. Cogeneration and
combined cycle plants have been introduced to achieve higher plant
efficiencies. To make efficient use of the high ash content coal available in
India, BHEL supplies circulating fluidized bed boilers to thermal and
combined cycle power plants. BHEL manufacturers 235 MW nuclear
turbine generator sets and has commenced production of 500 MW
nuclear turbine generator sets. Custom-made hydro sets of Francis, Pelt
on and Kaplan types for different head-discharge combinations are also
engineered and manufactured by BHEL is based upon contemporary
technology comparable to the best in the world & is also internationally
competitive.

Transmission
BHEL also supplies a wide range of transmission products and
systems up to 400 KV Class. These include high voltage power and

distribution transformers, instrument transformers, dry type

transformers, SF6 switchgear, capacitors, and insulators etc. For
economic transmission bulk power over long distances, High Voltage
Direct Current (HVDC) systems are supplied. Series and Shunt
Compensation Systems have also been developed and introduced to
minimize transmission losses.

A strong engineering base enables the Company to undertake turnkey

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

Transportation
A high percentage of trains operated by Indian Railways are equipped with
BHELs
traction and traction control equipment including the metro at Calcutta. The
company
supplies broad gauge electrical locomotives to Indian Railways and diesel
shunting
locomotives to various industries.5000/6000 hp AC/DC locomotives
developed and
manufactured by BHEL have been leased to Indian Railways. Battery
powered road vehicles
are also manufactured by the company.

International Operations
BHELs products, services and projects have been exported to over 50
countries
ranging from United States in the west to New Zealand in far East. The
cumulative capacity
of power generating equipment supplied by BHEL outside India is over
3000MW. The
companys overseas presence includes projects in various countries. A few
notable ones are :
150 MW (ISOI) gas turbine to Germany, utility boilers and open cycle gas
turbine plants to

Malaysia, Tripoli-west, power station in Libya executed on turnkey basis,

thermal power
plant equipment to Malta and Cyprus, Hydro generators to new Zealand and
hydro power
plant equipment to Thailand. BHEL has recently executed major gas-based
power projects in
Saudi Arabia and Oman, a Boiler contract in Egypt and several Transformer
contracts in
Malaysia and Greece

RENEWABLE ENERGY:Technologies offered by BHEL for non-conventional and renewable

sources of
energy include: wind electric generators, solar photovoltaic system, stand
alone and grid-interactive

solar power plants, solar heating systems, solar lanterns and batterypowered road vehicles. The company has taken up R&D efforts for
development of multi-junction amorphous solar cells and fuel cells based
systems.

INDUSTRIES
BHEL is a major contributor of equipment and systems to industries:
cement, sugar, fertilizer, refineries, petrochemicals, paper, oil and gas,
metallurgical and process industries. The company is a major producer of
large-size thyristor devices. It also supplies digital distributed control system
for process industries and control & instrumentation systems for power plant
and industrial application. The range of system & equipment supplied
includes: captive power plants, co-generation plants DG power plants,
industrial steam turbines, industrial boilers and auxiliaries. Water heat
recovery boilers, gas turbines, heat exchangers and pressure vessels,
centrifugal compressors, electrical machines, pumps, valves, seamless steel
tubes, electrostatic precipitators, fabric filters, reactors, fluidized bed
combustion boilers, chemical recovery boilers and process controls.
The Company is a major producer of large-size thruster devices. It also
supplies digital distributed control systems for process industries, and
control & instrumentation systems for power plant and industrial
applications. BHEL is the only company in India with the capability to make
simulators for power plants, defense and other applications

BHEL HARIDWAR
An Overview
At the foothills of the majestic Himalayas & on the banks of a holy Ganges in
Ranipur near HARIDWAR is located Heavy Electricals Equipment Plant of Bharat
Heavy electrical Ltd.

BHEL, wholly owned by the government of India is an integrated

engineering
complex consisting of several plants in India, where about 70,000
workers are busy in design & manufacturing of a wide range of heavy
electrical equipment. At present 70% of the Countrys electrical energy
is generated by the sets manufacturing by BHEL, Haridwar

BHEL HARDWAR is broadly divided in to two parts:

A) - CFFP: Central Foundry Forge Plant B) - HEEP: Heavy Electrical
Equipment Plant
A) - CFFP is divided in to following shops:

Forge Shop
Machine Shop
Steel Melting Shop (SMS)
Steel Foundry
Pattern Shop
Cast Iron (CI) Foundry

B) - HEEP is divided into following blocks:

BLOCK-1 Turbo Generators, AC Machines

BLOCK-2 Fabrication (Steam, Hydro & gas Turbine)
BLOCK-3 Gas & Steam Turbine
BLOCK-4 CIM (Coil & Insulation Manufacturing) & ACG (Apparatus
control Gear)
BLOCK-5 Heat exchangers, Forging and Fabrication

 BLOCK-6 Stamping
BLOCK-7 Wooden Packing works
BLOCK-8 Fabrication, seamless tubes and heat exchanger

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

**N volt

Where
= strength of magnetic field
= frequency in hertz
N = number of turn in stator winding
= frequency = P*n / 120
where,
P = number of poles
n = number of revolution per second of rotor

SYNOPSIS OF THE FUNCTION 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.

LARGE SIZE TURBO GENERATOR (LSTG)

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

Main types are:-

1. THRI
2. TARI
3. THDI
4. THDD
5. THDF
6. 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

COMPONENTS OF T.G. :STATOR

ROTOR

Stator frame
Stator core
Stator winding
End covers

Rotor shaft
Rotor winding
Rotor retaining rings.

BEARINGS
COOLING SYSTEM
EXCITATION SYSTEM.

STATOR The generator stator is a tight construction supporting and

enclosing stator winding, core and hydrogen cooling medium.
Hydrogen is contained within frame and circulated by fans
mounted at either end of rotor. The generator is driven by
direct coupled steam turbine at the speed of 3000 rpm.The
generator is designed for continuous rated output.
Temperature detector and other device installed or connected

within machine, permit the windings core and hydrogen

temperature, pressure, and purity in machine .

STATOR FRAME
Stator body is a totally enclosed gas tight fabricated structure made up
of high quality mild steel and austenitic steel. It is suitably ribbed with
annular rings in inner walls to ensure high rigidity and strength and it
also help to reduce vibration and to withstand the gas thermal
pressure .The arrangement, location and shape of inner walls is
determined by the cooling circuit for the flow of the gas and required
mechanical strength and stiffness. The natural frequency of the stator
body is well away from any of exiting frequencies. Inner and sidewalls
are suitably blanked to house for longitudinal hydrogen gas coolers
inside the stator body. It supports the laminated core and winding the
stator comprises an inner frame and outer frame. The inner cage is
usually fixed in the yoke by an arrangement of spring to damper the
double frequency vibrations inherent in two pole generator.

The fabricated inner cage is inserted in the outer frame after the stator
core has been constructed and the winding completed. Footings are
provided the stator foundation shields enclose the ends of heavy end
frame and form mounting of generator bear and radial shaft. R is
subdividing the frame and axial members to form ducts from which the
cooling given to end from radial duct in the core and is recirculated.
The horizontally mounted water cooled gas coolens being so arranged

the it may be cleaned on the water side without opening the machine
to atmosphere. All welded joints exposed to hydrogen are specially
made to prevent leakage. The complete frame is subjected to hydraulic
test at a pressure of 7 atm.

STATOR CORE
It consists of thin laminations. Each lamination made of number of
individual segments. Segments are stamped out with accurately
finished die from the sheets of cold rolled high quality silicon
steel.Before insulation on with varnish each segment is carefully
debarred. Core is stacked with lamination segments. Segments are
assembled in an interleaved manner from layer to layer for uniform
permeability. Stampings are held in a position by 20 core bars having
dovetail section. Insulating paper pressboards are also put between the
layer of stamping to provide additional insulation and to localize short
circuit. Stampings are hydraulically compressed during the stacking
procedure at different stages. Between two packets one layer of
ventilating segments is provided. Steel spacers arespot welded on
stamping. These spacers from ventilating ducts where the cold
hydrogen from gas coolers enter the core radialy inwards there by
taking away the heat generated due toeddy 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 losstest is done after
completion of core assembly.
The main features of core are
1. To provide mechanical support
2. To carry efficiently electric, magnetic flux.
3. To ensure the perfect link between core and rotor.

STATOR WINDING
The stator has a three phase, double layer, short pitched and bar type
of windings having two parallel paths. Each slots accommodated two
bars. The slot lower bars and slot upper are displaced from each other
by one winding pitch and connected together by bus bars inside the
stator frame in conformity with the connection diagram. Each bar
consists of solid as well as hollow conductor with cooling water passing
through the latter. Alternate arrangement hollow and solid conductors
ensure an optimum solution for increasing current and to reduce
losses. The conductors of small rectangular cross section are provided
with glass lapped strand insulation. A separator insulates the individual
layers from each other. The transposition provides for mutual
neutralization of voltage induced in the individual strands due to the
slots cross field and end winding field. The current flowing through the
conductor is uniformly distributed over the entire bar cross section
reduced. To ensure that strands are firmly bonded together and give
dimensionally stability in slot portion, a layer of glass tape is wrapped
over the complete stack. Bar insulation is done with epoxy mica
thermosetting insulation. This insulation is void free and posses 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.

INSULATION OF BARS
Vacuum pressed impregnated mica elastic high voltage
insulation:
The voltage insulation is provided according to the proven resin poor
mice base of thermo setting epoxy system. Several half overlapped
continuous layer of resin poor mica tape are applied over the bars. The
number of layers or thickness of insulation depends on the machine
voltage. To minimize the effect of radial forces windings hold and
insulated rings are used to support the overhang.
Corona protection:
To prevent the potential difference and possible corona discharges
between the insulation and the slot wall, the section of bars are
provided with outer corona protection. The protection consists of
polyester fluce tape impregnated in epoxy resin with carbon and
graphite as fillers. At the transition from the slot to the end winding
portion of the stator winding portion of stator bars a semiconductor
tape made up old polyester fluce is impregnated.
Resistance temperature detector :
The stator slots are provided with platinum resistance
thermometer to record and watch the temperature of stator core
and tooth region and between the coil sides of machine in
operation. All AC machines rated for more than 5 MVA or with
armature core longer the machine is to be provided with at least
6 resistance thermometers of their couples which shall built
inside the stator suitably distributed among the circumference
at the likely hottest point. The thermometer should be fixed in
the slot but outside the coil insulation. When the winding has
more than one coil side per slot, the thermometer is to be
placed between the insulated coil sides. The length of the
resistance thermometer depends upon the length of armature.

The leads from the detectors are brought out and connected to
the terminal board for connection to temperature meter or
relays operation of RTD is based on the prime that the electric
resistance of metallic conductor varies linearly with
temperature.

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

ROTOR
Rotor revolves in most modern generator at speed of 3000
revolutions per minute. It is also as electromagnet and to give it
necessary magnetic strength, the winding must carry a very high
current. The passage of current through windings generates heat.
But the temperature must not be allowed to become too high,
otherwise difficulties will be experienced with insulation. To keep the

temperature cross section of the conductors could not be increased

but this would introduce another problems. In order to make

room for large conductor, body and this would cause mechanical
weakness. With good design and great care this problem can be
solved.

ROTOR SHAFT

Details of shaft are given here

Length = 9 meter (approx.)
Diameter = 1 meter (approx.)
Material alloy steel
Number of poles = 2
The rotor shaft is cold rolled forging 26N1 or MOV116 grade and it is
imported
from Japan and Italy.
Rotor shaft is a single piece forming manufactured castings. It is forged
from a vacuum cast steel slots for insulation of the field winding are
made into the rotor body. The longitudinal slots are distributed over the
circumference. To ensure that a high quality product is obtained,
strength of material analysis and ultrasonic are performed during the
manufacturing rotor. The high mechanical stress resulting from the
centrifugal force and short circuit, torque called for a high specified
mechanical and magnetic properties as well as homogenous forging.
After completion, the rotor is balanced in the various planes and
different speed and then subjected to an over speed test at 120% of
rotor speed. The rotor consist of electrically active portion and two
shaft end approximately 60 b% of rotor body circumference have
longitudinal slots which holds the field winding. Slots pitch is selected
so that the two solid poles are displaced by 180 degree the rotor
wedges act as damper winding within the range of winding slots. The
rotor teeth at the rotor body are provided in radial and axial poles
enabling cooling air to be discharged.

ROTOR WINDING

The winding consist of several coils inserted into the slots and
the series connected such that two coils group to form one pole.
Each coil consist of several series connected turns each of which
consist of two half turns connected by brazing in end section.
The individual turn of coil are insulated against each other by
interlayer insulation. L-shaped strip of laminated epoxy glass
fiber with nomex filter are used for slot insulation.
The slot wedges are made up of high electrical conductivity material
and thus act as
damper winding. At their ends, the slots wedges are short circuited
through the rotor body.
When rotor is rotating at high speed, the centrifugal forces tries to lift
the winding out of
slots, they are contained by wedges.

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

CONDUCTOR MATERIAL
The conductors are made up of copper with silver content of
approx. 0.1% . As compared to electrolytic copper silver alloyed
copper features high strength properties at high temperature so

that coil deformations due to thermal stresses are eliminated.

The conductors are made of hard drawn silver bearing copper.
The rectangular cross section copper conductors have
ventilating ducts on the two sides thus providing a channel for
hydrogen flow. Two individual conductors placed-one over the
other are bent to obtain half turns. Further these half turns are
brazed in series to form coil on the rotor model

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

END WINDING BRACING

The spaces between the individuals coils in the end working are with
insulated members
that prevent coil movement the insulation by H or L high glass
lamination.

ROTOR RETAINING RINGS

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

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

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

BEARINGS
The turbo generators are provided with pressure lubricated selfaligning type bearing to ensure higher mechanical stability and
reduced vibration in operation. The bearings are provided with
suitable temperature element due to monitor bearing metal
temperature in operation.
The temperature of each bearing monitored with two RTDs (resistance
thermo detector) embedded in the bearing sleeve such that the
measuring point is located directly below Babbitt. These RTDs are
monitored temperature scanner in the control panel and if the
temperature exceeds the prescribe limit. Bearing have provision for
vibration pickup to monitor shaft vibration.

To prevent damage to the journal due to shaft current, bearings and

coil piping on either side of the non-drive and bearings are insulated

from the foundation frame. For fascinating and monitoring the

healthiness of bearing insulation, shaft insulation is provided.

VENTILATION AND COOLING SYSTEM

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

COOLING SYSTEM
STATOR COOLING SYSTEM
The stator winding is cooled by distillate water which is fed from one
end of the machine by Teflon tube and flows through the upper bar and
returns back through the lower bar of a slot. Turbo generator requires
water cooling arrangement over and above the usual hydrogen cooling
arrangement. The stator is cooled in this system by circulating
demineralized water trough hollow conductors. The cooling was used
for cooling of stator winding and for the use of very high quality of
cooling water. For this purpose DM water of proper specifying
resistance is selected. Generator is to be loaded within a very short
period. If the specific resistance of cooling DM water goes beyond
preset value. The system is designed to maintain a constant rate
cooing water flow through the stator winding at a nominal inlet with

temperature of 40 degree centigrade. As it is look working, the cooling

water is again cooled by water which is also demineralized to avoid
contamination with any impure water in case of cooler tube leakage
the secondary DM cooling water is in turn cooled by Clarified water
taken from clarified water header.

ROTOR COOLING SYSTEM

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

HYDROGEN COOLING SYSTEM

Hydrogen is used as a cooling medium in large capacity generally
in views of high heat carrying capacity and low density. But in
views sits forming an explosive mixture with oxygen. Proper
arrangement for puring, maintaining the purity in the generator
have to be made. Also in order to prevent used hydrogen from
generators, casing, sealing system is used to provide oil sealing.
The system is capable of performing following system

1. Filing in and purging of hydrogen safety without bringing in

contact with air.
2. Maintaining the gas pressure inside the machine at the
desired value at all the times.

3. Provide indication to the operator about the condition of the gas

inside the machine i.e. the pressure, temperature and purity.
4. Continuous circulation of gas inside the machine through a drier
in order to remove any water vapor that may be present in it
5. Indication of liquid level in the generator and alarm in case of high
level.

6.

GENERATOR SEALING SYSTEM

Seals are employed to prevent the leakage pf hydrogen from the

stator at the point of rotor exit. A continuous film between a rotor
collar and the seal liner is maintained by measurement of the oil at
pressure above the casing hydrogen gas pressure
.

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

This exciter generates electricity and this is of AC in nature. This AC is

that converted into DC and is that fed to turbo generator via C/C volt
for rectifying purpose. We have for RC bock and diode circuit. The most
beautiful feature is of this type of exciter is that is automatically
divides the magnitude of current to be circulated in rotor circuit. This
happens with the help of AVR regulator which means automatic voltage
regulator. A feedback path is given to this system which compares
theoretical value to predetermine and then it sends the current to rotor
as per requirement.

The brushless exciter mainly consists of:-

1.
2.
3.
4.

rectifier wheels
three phase main exciter
three phase pilot exciter
Metering and supervisory equipment.

The brushes exciter is an AC exciter with rotating armature and

stationery field. The armature is connected to rotating rectifier brides
for rectifying AC voltage induced to armature to DC voltage. The pilot
exciter is a PMG (permanent magnet generator). The PMG is also an AC
machine with stationery armature and rotating field. When the
generator rotates at the rated speed, the PMG generates 220 V at 50
hertz to provide power supply to automatic voltage regulator.

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

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

SCOPE
This produces the high voltage test on rotor winding
PURPOSE
This test is conducted to check whether the insulation is
properly placed or not.
3 This procedure for measurement of DC resistance of
stator and rotor winding of TG.

SCOPE
This procedure covers the measurement of DC resistance of stator
winding.

PURPOSE
This test is connected to measure the resistance content present in
the conducting material of stator and rotor.

3 Test procedure for measurement of impedance of rotor

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

TEST EQUIPMENTS
1.
2.
3.
4.
5.
6.

50 hertz power frequency AC source

AC voltmeter (0-30, 75, 150)
AC ammeter (0-5 ampere)
Multimeter
Current transformer (50/5 A)
Connecting leads

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

With 50 hertz, this test id done in following condition

1. Rotor outside the stator at standstill.

2. Rotor inside the stator at standstill.
3. Rotor inside the stator at speed 1/3, 2/3, 3/3 of rated speed.

ACCEPTANCE LIMIT-

IMPEDENCE WITH 50 HERTZ

As the impedance of the rotor winding depends on physical geometry

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

5 .Test procedure for measurement of leakage

reactance of TG stator winding

SCOPE
This procedure covers the leakage reactance measurement of stator
winding after completion of winding.

PURPOSE

1. To determine total leakage reactance Xl.

2. To determine core leakage reactance Xc.
3. To compute potier reactance Xd.
6. Test procedure for capacitance measurement of stator winding.

SCOPE
The procedure covers the measurement of capacitance per phase with
respect to ground of the stator winding.

PURPOSE
To generate reference value for comparison in future at site.

PRINCIPLE
The stator winding have two values of capacitances.

1.Cg capacitance with respect to ground called ground capacitance.

2.Cm capacitance with respect to other winding called mutual
capacitance.

HELIUM LEAK TEST

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

MOTOR WINDING
Technical Requirements

1. Count the coil groups in the anti clock wise direction locking from
the connection end.
2. Leads of the coils groups lying on the outer periphery of the
overhang position shall be the finish and those lying on the inner
periphery shall be the start to coil groups.
3. Leads shall be taken form the coil side lying at inner periphery of
slot No.1.
4. The coil group No.1 shall Lie at top with its axes coinciding with
the vertical axis of the frame.

5. Take out terminal leads 02 U2, V2, W2 for left hand side terminal
box and 02 U1, V1, W1 for right hand side terminal box. When
looking form the connection end.

Circuit diagram:

WINDING DIAGRAM OF MOTOR

Winding data :
NO. OF PHASE

NO. OF POLES

PHASE CONNECTION

NO. OF PARELLEL PATH

NO. OF COIL GROUP

18

Connection of motor winding :

CONCLUSION
Training at B.H.E.L. has proved to be quite faithful. It proved an
opportunity for encounter with such huge machine like turbogenerators.

The architecture of B.H.E.L., the way various units are linked and
the way working of whole plant is controlled make the students realize
that Engineering is not just structural description but greater part is
planning and management. It provides an opportunity to learn tech.
Used at proper place and time can save a lot of labour.

But there are few factors

in true spirit. It is
recommended

that require special mention. Training is

not carried
that there should be projectors especially
for trainees

where presence of authorities is ensured.

However, training has proved to be satisfactory. It has allowed us

an opportunity to get an exposure of the practical implementation of
theoretical fundamentals.