BHEL INTRODUCTION:

Bharat Heavy Electricals Limited (BHEL) is the largest

Engineering and Manufacturing Enterprise of its kind in the public sector
in India. It ranks among the top twelve organizations in the world,
engaged in the manufacture of power generation equipment. The
company provides products, systems and services in the fields of Energy,
Industry and Transportation.

BHEL has 14 manufacturing plants and 4 power sector repair

divisions. A vital link to this chain of BHEL manufacturing units is the
unit at Ramachandrapuram, Hyderabad. BHEL manufactures turbo-
generators of ratings upto 200MW for industrial applications and for
power generation to Thermal Power Stations. BHEL supplied sets
account for nearly 56318 MW on 65% of total installed capability to
produce thermal power plants upto 1000MW rating and gas turbines upto
240 MW. Cogeneration and combination cycle plants have been
introduced.

BHEL manufactures 235 MW nuclear turbine generator set and

commenced production of 500 MW nuclear generator set. BHEL is a
major producer of large size thyristor device and digital distributed
control systems. BHEL supplies a wide range of transmission products &
systems. HVDC systems are also supplied. The cumulative capacity of
power generating equipment supplied by BHEL outside India is 3000
MW.

Major BHEL manufacturing units are located in the following

places namely HARIDHWAR, BHOPAL, JHANSI, TRICHY,
HYDERABAD AND BANGALORE.

BHEL Hyderabad is a vital link in country wide network . Here

total quality management (TQM) is the hallmark, excellence in
performance is the prime concern.
BHEL Hyderabad is manufacturing the following products:

1. Steam Turbines.
2. Gas Turbines.
3. Generators.
4. Heat Exchangers.
5. Boiler Feed Pumps.
6. Pulverisers.
7. Switch Gears.
8. Centrifugal Compressers and
9. Oil Rigs.

Here in BHEL, Electrical Machine- 02 Manufacturing department,

manufactures a wide range of steam turbine generators and gas turbine
generators with matching Brush less exciters.

Keeping pace with the latest development in insulation systems to

optimize the design, BHEL, Hyderabad has installed the micalastic (VPI)
system of insulation. The Generators are manufactured here with the state
of the Art technology of insulation i.e., VACCUM PRESSURE
IMPREGNATION SYSTEM (or) RESIN POOR INSULATION
SYSTEM upto a capacity of 125 MW and planning to reach capacity
upto 235 MW.
 INTRODUCTION:

Power is the basic necessity for the economic development of a

country. The production of electrical energy and its per-capita
consumption is deemed as an index of the standard of living in a nation in
the present day civilization. Development of heavy or large scale
industries as well as medium scale industries, agriculture, transportation
etc., totally depend on electric power resources of energy with utmost
care and with maximum efficiency. It is the duty of engineers and
scientists to find out ways and means to supply required power at
cheapest rate. The per-capita consumption on average in the world is
around 1200 KWH. The figure is very low for our country and we have
to still go head in power generation to provide a decent standard of living
for people. The need for immediate increase in the country’s power
production is vital and it is our duty to utilize the available resources in a
better possible manner.

Broadly power plants may be classified as under: -

1. CONVENTIONAL POWER GENERATING

SYSTEMS.

 Steam (Thermal) Power Plant.

 Hydro Electric Power Plant.
 Nuclear Power Plant.
 Diesel Power Plant.
 Gas Turbine Power Plant.
2. NON-CONVENTIONAL POWER GENERATING
SYSTEMS.

 Solar Power Plant.

 Wind Power Generation.
 Tidal Power Generation.
 Geo-Thermal Power Plant.yj7

The principal resource for power generation in our country is

dominated by Coal. About 60% of power requirement is generated by
thermal power plants in which steam is the working fluid. Steam is
produced in a boiler using coal as fuel and is used to drive the prime
mover, usually the steam turbine. In the steam turbine heat energy is
converted in to mechanical energy, which is used for generating electric
power. The combination is known as STG (Steam Turbine Generators).
The construction procedure for gas and steam turbo generators remains
the same. For STG the output terminals are down and for GTG the
terminals are at the top. In generator construction, the bars are laid in the
slots and end connections are made using bracing. The wounded stator is
subjected to D.C test and carried to VPI plant for impregnation. After the
VPI process the stator is again tested and is assembled with Rotor and
exciter and all other auxiliary equipments.

TURBO GENERATORS:

PRINCIPLE:

A generator works on the principle of Faraday’s Law Of Mutual

Induction. According to Faraday, when a conductor is moved in a
magnetic field or when the magnetic field is moved across the stationary
conductor, an EMF is induced in the conductor, when the conductor cuts
the flux produced by the magnetic field. A current flows through the load
when the circuit is closed.
 A.C generators can be broadly classified in to two types. They are:

 SYNCHRONOUS MACHINES:
Synchronous generators (or) Alternators are those in which the
speed of the rotor and flux are in synchronism.

 ASYNCHRONOUS MACHINES:
These are the machines in which the flux speed and rotor speed will
not be same. Ex: Induction Motors.

The 3 Phase Synchronous generators are the widely used machines

for power production on large-scale basis. These when connected to
various turbines, they are sometimes called as Turbo-alternators. Gas
turbine generators and steam turbine generators are famous and widely
used for power generating purpose.

A 3 phase synchronous generator basically consists of two parts.

 Stator: Stationary part of the generator, used as the Armature.

 Rotor: The purpose of which is to generate the alternating flux.

Synchronous generators can be classified in to various types based

on the medium used for generation. They are:
 Turbo-Alternators Steam (or) Gas.
 Hydro Generators.
 Engine Driven Generators.

COMPONENTS OF GENERATOR:

The generator consists of the following components:

 STATOR

Stator Frame.
Stator core.
Stator Winding.
Stator end covers.

 ROTOR

Rotor Shaft.
Rotor Winding.
Rotor Retaining Rings.
Field Connections.

 BEARINGS

 AIR COOLERS

The following additional auxiliaries are required for generator

operation.

 OIL SUPPLY SYSTEM.

 EXCITATION SYSTEM.

STATOR:
The stator is manufactured as a two-part structure, the Outer
Casing and an Inner Frame-support for core and windings.

STATOR OUTER CASING:

To facilitate manufacturing and assembly, the stator consists of the
following main components.
1. Lower part of outer casing.
2. Upper part of outer casing.
3. Inner frame with core and windings.
4. Labyrinth rings.

OUTER CASING:
The outer casing is fabricated from structural steel and consists of
a lower part and an upper part. The inner frame with the electrically
active parts of the stator is supported resiliently in the lower part of the
outer casing.

A rigid outer casing is required due to the forces and torques

arising during operation and transmitted to the foundation via. the welded
stator feet.

The inside surface of the welded outer casing is stiffened by means

of a large number of radial and axial ribs. The arrangement and
dimensioning of the ribs are determined by the cooling air passages and
the required mechanical strength. Dimensioning is also indicated by the
vibrational considerations, resulting partly in greater wall thicknesses
than required from point of view of mechanical strength. Opening in the
outer casing provide flow paths for the cooling air and serve for installing
the terminal bushings at the exciter end. The opening in the end walls are
sealed with LABYRINTH RINGS bolted in position at the ends.

STATOR INNER FRAME WITH CORE:

The purpose is to provide

 Mechanical Support and
 Cooling Provision.

After stacking of the stator core, the insulated guide bars are
installed in the respective slots. The required stiffness obtained by
welding rings to guide bars and pressure plates. All the three rings of the
caged core are welded with feet and supported resiliently in the outer
stator frame.

ANCHORING THE STATOR TO THE FOUNDATION:

The stator frame is anchored to the foundation with slot plates and
anchor bolts, the sole plates being solidly bolted to the foundation
through the anchoring bolts.

The stator frame is placed on the sole plates, aligned with slims and
then rigidly connected to the sole plates by means of bolts.

Different thermal expansions of the stator and foundation result in

differential movements between the stator frame and machine sole,
plates. The stator is therefore fixed n a position so that smooth running of
the rotor will not be impaired. Davel pins located in the stator feet and
machine sole plates secure the stator in position.

COOLING:
Cooling is one of the basic requirements of any generator. The
effective working of generator considerably depends on the cooling
system. The insulation used and cooling employed are inter-related.

The various losses in the generator are broadly classified as below:

1. Iron Losses / Core Losses / Magnetic Losses / Constant Losses.
2. Hysterisis Losses.
3. Eddy Current Losses.
4. Copper Losses / I2R Losses / Windage Losses.

These losses in the generator dissipates as the heat, it raises the

temperature of the generator. Due to the high temperature, the insulation
will be affected greatly. So the heat developed should be cooled to avoid
excessive temperature rise. So, the class of insulation used depends
mainly on the cooling system installed. There are various methods of
cooling. They are:

1. Air Cooling – 60MW.

2. Hydrogen Cooling – 100MW.
3. Water Cooling – 500MW.
4. H2 and Water Cooling - 1000MW.

Hydrogen Cooling has the following advantages over AIR cooling:

1. Hydrogen has 7 times more heat dissipating capacity.

2. Higher specific heat.
3. Since Hydrogen is 1/4th of air weight, it has higher compressibility.
4. It does not support combustion.

DISADVANTAGES:
1. It is an explosive when mixed with oxygen.
2. Cost of running is higher.

Higher capacity generators need better cooling system.

The two-pole generator uses direct air-cooling for the rotor

winding and indirect air-cooling for the stator winding. The losses in the
remaining generator components, such as iron losses, windage losses and
stray losses are also dissipated through air.

The heat losses arising in the generator interior are dissipated

through air. Direct cooling of the rotor essentially eliminates hot spots
and differential temperatures between adjacent components, which could
result in mechanical stresses, particularly to the copper conductors,
insulation and rotor body. Indirect air-cooling is used for the stator
winding.

The cooling air for the axial-flow ventilated generator is drawn by

axial-flow fans arranged on the rotor via lateral openings in the stator
housing. Hot air is discharged via three flow paths after each fan.

FLOW PATH 1:

It is directed into the rotor end winding space and cools the rotor
winding, part of the cooling air flows past the individual coils for cooling
the rotor end winding and then leaves the end winding space via. bores in
the rotor teeth at the end of the rotor body. The other portion of the
cooling airflow is directed from the rotor end winding space in to the
slot-bottom ducts from where it is discharged in to the air gap via. a large
number of radial ventilating slots in the coils and bores in the rotor
wedges. Along these paths the heat of rotor winding is directly
transferred to the cooling air.

FLOW PATH 2:

It is directed over the stator end winding to the cold air ducts and
into the cold air compartments in the stator frame between the generator
housing and rotor core. The air then flows
into the air gap through slot in the stator core where it absorbs the heat
from the stator core and stator winding.

FLOW PATH 3:

It is directed in to the air gap via. the rotor-retaining ring. The air
then flows past the clamping fingers via. ventilating slot in the stator core
into the hot air compartments in the stator frame being discharged to the
air cooler. The flow path mainly cools the rotor retaining rings, the ends
of the rotor body and the ends of the stator core.

Flows 2&3 mix in the air gap with 1 leaving the rotor. The cooling
air then flows radially outward through ventilating slots in the core with
in the range of hot air compartments for cooling of the core and winding.
The hot air is discharged to air cooler.
STATOR CORE:

The purpose of stator core is to

 Support The Winding and
 Carry the Flux.

So, the selection of material for building up of core plays a

vital role. The losses i.e., magnetic losses are mainly of two types
 Hysterisis Losses:
Due to the residual magnetism in the material.
 Eddy Current Losses:
Due to the EMF produced in the core of the stator.

In order to minimize the Hysterisis losses, Silicon alloyed

steel sheets are used for building up of core. The sheets has following
composition:
Steel - 95.8%.
Silicon - 4.0%.
Impurities - 0.2%.

The sheets are 4% SILICON ALLOYED COLD ROLLED NON-

GRAIN ORIENTED SHEETS (CRNGO). To reduce the eddy current
losses, the core is build up of 0.5 mm thickness laminations, which are
insulated from each other. The sheets are insulated by CLASS-B type of
varnish.

LAMINATION PREPARATION:

The core is built up of 6 sectors, each of 60C cut according to the

specifications. The cut steel is punched for slots and deburred upto 5
micron. Depending on the temperature withstandability of the machine
the laminations are insulated by varnish.
INSULATION CLASSES Y A E B F H C

TEMPERATURE 90 105 120 130 155 180 >200

The insulation used is ALKYD PHENOLIC VARNISH dried at

suitable temperature. The lamination sheets are passed through a
conveyer, which has an arrangement to sprinkle the varnish, and the coat
of varnish is obtained. The sheets are dried by series of heaters at a
temperature of around 260-350C. Two coatings of varnish are provided
in the above manner till 12-18 micrometer thickness of coat is obtained.
Each lamination should be dried for around 90 sec at constant speed. The
prepared laminations are passed for various tests.
 Xylene Test – For proper coat of varnish.
 Mandrel Test- When wound around mandrel there should be no
cracks.
 Viscosity Test- It should be 40-45cp.
 IR value test- For 20 layers the insulation resistance should have a
minimum value of 1 Mega Ohm.
 Hardness Test-Minimum 7H pencil hardness.
 Uniformity Test- Coating Uniformity.

The core is stacked with lamination segments in individual layers

while being supported on the pressure plate with its welded clamping
fingers. The segments are staggered from layer to layer so that a core of
high mechanical strength and uniform permeability to magnetic flux is
obtained. Stacking mandrels and bolts are inserted in to the windings slot
bores during stacking provide smooth slot walls.

To obtain the maximum compression and eliminate under setting

during operation, the laminations are hydraulically compressed and
heated during the stacking procedure when certain heights of stacks are
reached. The complete stack is kept under pressure and located in the
frame by means of clamping bolts and pressure plates.
 The clamping bolts running through the core are made of non-
magnetic steel and are insulated from the core and the pressure plates.

The pressure is transmitted from the pressure plates to the core by

clamping fingers. The clamping fingers extended up to the ends of the
teeth, thus ensuring a firm compression in the area of the teeth.

The stepped arrangement of the laminations at the core ends

provides for an efficient support of the tooth portion and in addition
contributes to a reduction of eddy current losses and local heating in this
area due to end leakage flux. The clamping fingers are made of non-
magnetic steel to avoid eddy current losses. After compression and
clamping of the core, the core key bars are inserted into the slots
provided in the back of the core and welded to the pressure plates. All
key bars, except one are insulated from the core. To provide the
grounding of the core along its entire length, a copper rope is inserted
between one grooved key bar and core.

To remove the heat, spacer segments are placed at intervals along

the core length, which divide the core into sections to provide wide radial
passages for cooling airflow. In the core end portion, the cooling air ducts
are spaced more closely to account for the higher losses and to ensure
more intensive cooling of the narrow core sections.

The core building or assembling method depends on the insulation

system used.

1.For Resin Rich system, the laminations are stacked in the frame itself.
2.For Resin Poor system (or) VPI system, cage core (or) open core design
is usually employed.

STATOR WINDING:
GENERAL:

The three-phase stator winding is a fractional pitch two layer type

consisting of individual bars. Each stator slot accommodates two bars.
 It is a double layer lap winding with 60 degree phase spread
fractional windings, used to reduce higher order harmonics and pitch of
the winding is so selected that 5th and 7th harmonics are greatly reduced.

The slot bottom bars and top bars are displaced from each other
by one winding pitch and connected at their ends to form coil groups.

The coil groups are connected together with phase connecters

inside the stator frame. This arrangement and shape of the bars at the
ends result in a cone shaped winding having particularly favorable
characteristics both in respect of its electrical properties and resistance to
magnetically induced forces. The bars afford maximum operating
reliability since; each coil consists of only one turn insulation and the
main insulation identical.

1.CONDUCTOR CONSTRUCTION:

The bar consists of large number of separately insulated copper

strands, which are transposed to reduce the skin effect losses.

TRANSPOSITION OF BARS:

The individual copper bars are transposed 360 to equalize the

induced EMF in all strands, to minimize the circulating currents and skin
effect also gets minimized and it gives a good rigidity to the bar.

This bar winding is called as roebel bar winding having two bars
in each slot. The roebel bar consists of large number of conductors
insulated from each other and transposed for 360 or in multiples of 180
connected to each other in parallel. The conductors are put in two layers
along the width of the stator slot. The conductor in a roebel bar is so
twisted that each one of them occupies all possible positions along the
height of the slot. This roebel transposition greatly reduces the eddy
current losses in conductors.
2.HIGH VOLTAGE INSULATION:

A generator designed for high voltages required a high level of slot

insulation. BHEL hyderabad has the facility for the following two
methods of insulation.
 RESIN RICH SYSTEM.
 RESIN POOOR SYSTEM (OR) VPI METHOD.

Actually resin rich system became obsolete, since VPI system is

giving good insulation at lower cost and with less process time cycle.

3.RESIN POOR SYSTEM:

In this method the transposed bars are wrapped with dry mica glass
fabric tape applied from end to end. The tape is a composite tape built up
from a thin, high strength backing material to which mica is bonded by a
small amount of epoxy, as an adhesive for further processing. The bent
bars are then provided with a final protective wrapping of highly flexible
glass fabric tapes in order to obtain a smooth surface.

ICP-
 Also called Inner Potential grading on the stack of the bars to avoid
inner discharges.
 To optimize insulation thereby voltage stress grading.
 Provided with conductive fleece tape with a copper strip.

OCP-
 On the outer surface of the insulated stator bars.
 Conductive fleece tape.
 To provide effective path for outer corona discharges.

ECP-
 Semi conductive tape on both ends of the straight part of the bars.
 to dampen the voltage surges through additoral surface
capacitance.
4.BAR LAYING IN STATOR SLOTS:

After forming stator core with laminations, the Assembled core is

placed in Stator Winding Room Before laying of the coil in stator slot.
The slots are cleaned with compressed air to remove any foreign
materials present with in the slots. Before placing of the Bottom bar in
the stator slot the bar is pressed for 15-20 minutes in a hydraulic press. A
conductive fleece material is placed and then insulated conductive bar is
placed in the slot and then the bar is adjusted with coil pitch and it is tied
to the end ring. In overhang portion, the successive coils are separated by
placing the spacers. Then spacers are taped by insulating tape and then
tied to holders. An insulating layer is placed on the bottom bar, and then
top coils are laid in the stator slots same as bottom bars. Wedging is done
in the stator slots by planting the wedge of HGL (Hardened Glass
Laminate) material. This gives a good strength to the coils.

5.BRACING OF STATOR OVERHANG:

After laying all the coils in the insulated slots, bracing is done in
overhang portions. Electromagnetic force is produced in the stator
overhang due to attraction between conductors carrying current in the
same direction and due to repulsion between conductors carrying in the
opposite direction. Under normal conditions the electromagnetic forces
produced by current carrying conductors are negligible. But during
sudden Short Circuit at the line terminals, the current in the winding may
rise to about 15 times the full load current and the electromagnetic forces
being proportional to square of current may rise to about 250 times the
force under normal full load conditions. These forces may be either
tangential or radial. Conductors in the same phase tend to bunch
themselves together, while conductors in different phases may suffer
repulsion. Any movement of overhang tends to pull the slot conductors
outwards and may result in cracking of insulation at the core ends. Thus
the conductors in the overhang must be braced i.e., their mechanical
strength be raised.
 A method, which is still widely used, employs one or two circular
insulated rings to support the overhang against radial forces. There, 4-6
steel brackets in turn support rings. The use of steel rings and supporting
brackets have the following disadvantages.

 The steel rings have to be heavily insulated with mica.

 There is a large core loss in the steel rings produced by the leakage
flux especially in the large generators with large pitches due to this
loss the rings get overheated, damaging the ring insulation.

6.STATOR END WINDINGS:

The insulated bars are placed in the slots of the stator core. All gaps
and spaces due to the design and manufacturing are filled with pads of
glass fabric mat capable of being impregnated.

After installation of the bars DC tests are performed to promptly

identify and correct any weak point in the insulation. In the slot section of
the stator core, the bars are secured in position with slot wedges outside
the slot section. The bars are shaped so that the windings are placed in the
slots, cone shaped end windings are obtained. A small cone taper is used
to keep the strain losses to minimum.

In the end winding areas, the involute shaped individual bars are
arranged in parallel and uniform spacing. To obtain a short circuit proof
structure, the bars are lashed to winding supports and support rings over
pads of dry glass fabric mat with dry glass fabric tapes.

Both the bottom bars and top bars thus form a cone shaped layer
each of which ensures mutual support of the bars.

7.CONNECTION OF BARS:

Brazing makes the electrical connection between the top and bottom
bars. One top bar strand each is brazed to one strand of associated bottom
bar so that beginning of each strands is connected without having any
electrical contact with the remaining strands. This connection offers the
advantage that circulating current losses in the stator bars are kept small.
The strands are insulated from each other at the brazed joints. The coils
connected are wrapped with dry mica/glass fabric tapes applied half
overlapped. The thickness of wrapper depends on the machine voltage.
The gaps between the individual coil connections being sufficiently large,
no additional insulation is required.

8.PHASE CONNECTORS:

The phase connecters consist of flat copper sections, the cross

section of which results in a low specific current loading. The
connections to the stator winding are of revetted and soldered tape and
are like-wise wrapped with dry mica/ glass fabric tapes.

The phase connecters are firmly mounted on the winding support,

using clamping pieces and glass fabric tapes.

TERMINAL BUSHINGS:

1.ARRANGEMENT OF TERMINAL BUSHINGS:

The beginning and ends of the three phase windings are brought out
from the stator frame through terminal bushings, which provides for high
voltage insulation. The bushings are bolted to the stator frame at the
exciter end by their mounting flanges. Bushing type current transformers
for metering and relaying may be mounted on the bushings outside the
stator frame. The generator main leads are connected to the terminal
connectors outside the stator frame.

2.CONSTRUCTION OF TERMINAL BUSHINGS:

The bushing conductor consists of high conductivity copper buses.

All connection flanges are silver-plated to minimize the contact
resistances of the bolted connections. The supporting insulator of glass
silk cloth is impregnated with epoxy resin. The copper buses are attached
to the insulator only at one end and are thus free to expand. Flexible
connectors allow for thermal expansion between terminal bushing and
the phase connectors.

To prevent eddy current losses and inadmissible overheating, the

mounting flange is made of glass silk cloth as well.

3.COOLING OF TERMINAL BUSHINGS:

To dissipate the heat, the terminal bushings are directly cooled with
cold air. Cold air from the discharge end of the fan is pressed in to the
insulator. The hot air is returned to the suction in take of the fan via. the
passage between the two copper buses.

INTRODUCTION TO INSULATION SYSTEM:

In Electrical Machines insulation is most important requirement to

sustain high voltages and basically insulation is the heart for electrical
machines. Insulation is the property, which has enormous resistance to
the conductivity. Basically, in insulating materials the forbidden gap
between valency and conduction bands is very large. The property of
good insulating material is non-conductive towards electricity and
conductive towards heat. A good insulating material needs the following
properties:

 The basic function of insulation is to provide isolation to live wire or

live wire to earth.
 It should be good conductor to heat and bad conductor to electricity.
 It should withstand the designed mechanical stress.
 It should have good chemical and thermal resistivity and
environmental resistivity.
In order to achieve good insulation properties the following process are
vogue in BHEL.

1. THERMOPLASTIC PROCESS OF INSULATION.

2. THERMOSETTING PROCESS OF INSULATION.

BHEL is practicing only thermosetting process of insulation, basically of

two types.

 RESIN RICH SYSTEM OF INSULATION.

 RESIN POOR SYSTEM OF INSULATION.

RESIN RICH SYSTEM:

Resin rich system of insulation for all electrical machines in

Insulator, employed in olden days contains nearly 40% of EPOXY
RESIN. So it gives good thermal stability. Resin Rich Insulation consists
of the following materials in percentage.

1. MICA PAPER TAPE- 40-45%.

2. GLASS PAPER TAPE-20%.
3. EPOXY RESIN-40%.

The bars are insulated (or) taped with RESIN RICH TAPE and
placed in the pre-assembled stator core including stator frame.

An insulator should satisfy the following properties for any electrical

system.
1. ELECTRICAL PROPERTIES.
2. MECHANICAL PROPERTIES.
3. THERMAL PROPERTIES.
4. CHEMICAL PROPERTIES.

In resin rich system of insulation Mica paper will give a good

dielectrical strength and Glass fiber tape will give good mechanical
strength and Epoxy Resin can withstand upto 155C. So, it gives good
thermal properties. Resin rich and Resin poor insulating materials are
characterized by the contact of the Epoxy resin. In Resin rich system, the
contact of Epoxy resin tape is 40% whereas in Resin poor system, it is
only 8%. By VPI Impregnation process, the required amount is added to
the conductor bars after assembling the core and placing the windings in
the core. In resin rich system before placing of coils in the stator slots, the
resin rich tape will be wrapped over the bars. But this system has the
following disadvantages:

1. This system is very time consuming and very long procedure.

2. Total cost of system is more.

In order to minimize the overall cost of machine and to reduce the

time cycle of the system, the VACCUM PRESSURE IMPREGNATION
SYSTEM is being widely used. The process is very simple, less time
consuming and lower cost.

BHEL Hyderabad is equipped with the state of the art technology of

VACCUM PRESSURE IMPREGNATION.

VACCUM PRESSURE IMPREGNATION:

GENERAL:

The VPI system was brought by Dr.MEYER with the collaboration

of WESTING HOUSE in the year 1956. The Resins used were of
Polyester. SIEMENS developed the present VPI system with Epoxy resin
and treated accelerator on tapes. The Mica tapes used for VPI system are
ROG275, ROG275.1 and ROG292. ROG275 tapes are with Glass cloth
backing upto 13.8KV voltage level. ROV292 mica papers are with
polyester fleece above 13.8KV machines. The advantage of fleece is, for
better and more penetration of resin. ROG275.1 tape is special glue
varnish for tropical countries like India and Brazil to resist higher
humidity. The glue being used for main insulation tape is X2026 and for
conductor insulation is X2027.VPI system can be useful for manufacture
of insulation and also windings are guaranteed to expected quality.

BHEL, Hyderabad had installed the state of the art technology of

VACCUM PRESSURE IMPREGNATION SYSTEM for cage stators up
to 125MW capacity, which is largest of its kind in India. This system
conforms to the latest insulation system adopted by KWU-SIEMENS
technology. The stator coils are taped with porous resin poor mica tapes
before inserting in the slots of cage stator. Subsequently wounded stator
is subjected to a special VPI process, in which first the stator is vacuum
dried and then impregnated in a resin bath under pressure of Nitrogen
gas. Then the stator is cured in an oven.

The main characteristics of this insulation system are:

1. Better heat transfer resulting from penetration into minute air gaps in
between laminations and bar insulation.
2. Low dielectric loss resulting in increased life of insulation and so of
the machine.
3. High resistance against the effect of moisture.
4. Reduction of time cycle of insulation.

The Resin used for VPI is ET884, a mixture of epoxy resin E1023
(leekuthermx 18) and hardener H1006 in 1:1.2 ratio by weight.

E1023: The Resin is in drums of 220 kg by weight. It is in crystal form at

a temperature of 20C. The container is not completely filled with resin.
In practice 200 or 190 kgs. Resin is available in the drums. The reason is
that after heating in the furnace, the Resin in liquid state shall not come
out of the container. The Drums are kept in Oven and heated upto 100C
for about 18 hours. Every drum is to be weighted and looked into for the
state of condition of resin before and after heating. If resin is not fully in
liquid condition, it can be heated upto 125C. The storage tank is filled
with resin first depending upon the volume and ratio of mixture at a
temperature of 60C through noise pipes. Resin filling is being done by
creating 0.2 bar vacuum in the tank.

RESIN MIXTURE:
The mixing ratio of resin to hardener is 50:50 parts. No warming
up of hardener is required. The Resin mixture required for the BHEL
impregnation tank is 9000 lts.

SIZE OF THE TANK:

The size of the tank is 4000 mm diameter and 9000 mm in height.

HERAUEUS IMPREGNATION CIRCUIT:

Three storage tanks each of resin capacity 9000lts are in operation
for setting the resin mixture. Cooling and Heating cycle is by circulating
the resin through heat exchangers. Brine solution heated by steam is
being used for heat exchangers.

PROPERTIES OF MICALASTIC:
The Micalastic post-impregnation process ensures a mechanically
firm bond between all winding components and between the winding and
the stator, which is capable of withstanding the various temperature rises
occurring during operation. The Micalastic system thus provides for
reliable insulation, applied continuously from end to end on stator bars
providing effective protection against over voltages arising during normal
operation and against the high stresses that may occur at the slot ends
when high-test voltages are applied.

1. Micalastic has a long electrical life as determined on hundreds of

experimental bars and verified on numerous full size bars.

2. Micalastic is a good conductor of heat by reason of its high mica

content and the void free synthetic resin. Efficient heat transfer is
particularly important for dissipation of the upper losses in machines
that require thick insulation because of the high voltages and are not
designed with direct cooled windings.
3. Micalastic feature a high thermal stability. The resin impregnation and
cured insulation permits the machine to be operated continuously
under conditions corresponding to those for class F insulation.

4. Micalastic insulation shows only a small dissipation factor tip-up with

increasing temperature, which is also affected by the loss attributable
to the voltage grading material applied at the slot ends.

5. Micalastic features an elastic response to thermo mechanical stresses.

Alternate heating and cooling with large difference in temperature are
endured without detrimental effects on quality. The Micalastic
insulation remains firmly bonded to the copper conductors and the
stator. This confirmed by the dissipation factor measured with rising
voltage within operating temperature range.

6. Micalastic owes its insensitivity to high temperatures and temperature

changes to cured synthetic resin. This favorable performance under
thermal stress is particularly advantageous for machines subject to
frequent load change, e.g. generators driven by gas turbines or peak
load generators in steam power plant.

7. Micalastic does not burn. The insulation features such a low

flammability that even on arcing it does not continue to burn once the
arc has been extinguished. Fire extinguishing system such as CO2
bottle racks is therefore not necessary for Micalastic insulated
windings.

8. Micalastic provides protection against moisture due to its

impregnation with synthetic resin which seals the winding completely.

9. Micalastic is highly resistant to chemical action. Corrosive gases,

vapor, lubricating oil, weak acids or alkalis to which, the windings
may be exposed under unfavorable conditions do not attack the
insulation. The impregnating Resin does not react with chemicals.
 VACUUM PRESSURE IMPREGNATION INSULATION
PROCESS

Here in BHEL, they are using Horizontal Impregnation chamber

for higher capacity stators of steam turbine (or) Gas turbine generators
and vertical impregnation chamber for smaller capacity systems such as
Permanent Magnet Generator stators for brush less excitation systems,
coil insulation of small pumps and armature of motors etc.,

In the following steps Vacuum Pressure Impregnation of stator

winding has been discussed.

PREHEATING THE JOB:

The completed stator is placed in impregnation vessel and this

vessel is kept in an oven for a period of 12 hours at a temperature of
60C. Six thermocouples are inserted at the back of the core to measure
the temperature. The temperature should not exceed 85C. The smaller
stator can be directly installed in impregnation chamber.

JOB INSERTION IN THE IMPREGNATION CHAMBER

AT 60C:

The preheated job next will be placed in the impregnation

chamber by opening the lid of the chamber by hydraulic mechanism. The
vessels are kept clean. Resin available in the vessel is wiped out.
Methylene, traces of resin are not allowed on the inner side of the tank. It
reacts with humidity and scale formation will takes place. These pieces at
the time of main resin flow will mix and block the penetration of Resin in
to component and obstruct the filters also. The resin at the time of
cleaning is carefully removed by rubbing with rubber sheets. The inner
vessels are also cleaned by keeping the vessel slant position on the
ground. After ensuring the perfect cleaning, the tank should be allowed
for further operations. The impregnation vessel containing the preheated
job will be placed in the impregnating chamber. The lead of the chamber
is allowed to close by hydraulic motor. The inside temperature of the
impregnation chamber should not be less than 60C. The inside
temperature is measured by placing the thermocouples at the backside of
the core.

The cooling and heating of the impregnation chamber was done

through heat exchangers. The fluid used in heat exchangers is Brine
solution. When the lid of the chamber is closed, silicon Grease is applied
on the surface of the chamber where the lid is touching. A rubber gasket
is also provided on the rim not to allow any leakage. Air pipes are closed
and vacuum pumps will be started.

VACUUM CREATION:

After inserting the warm tub with job in to the impregnation

chamber by keeping the RTD elements on the job, the lid of the chamber
will be closed. The vacuum is created in the chamber up to 0.2mbar for
duration of 17 hours by using air suction pumps. Vacuum is created in the
chamber to remove any moisture present in the stator core and chamber,
because this is the most important factor considered during the
manufacture and operation of generator as it greatly affects the dielectric
strength of insulation.

The job temperature is to be maintained always above 60C. If

found less, the tank can be heated up. In practice the vacuum can be
created in 15-17 hours. During this time the Resin cooling is being
carried out to reach 10C and heated up automatically to 60C.

The chamber is heated up automatically by circulating the hot

Brine solution through the surface of the impregnation chamber. Heat
exchangers will heat up the Brine solution. Cooling is also done by the
same Brine solution.
IMPREGNATION:

The resin mixture is to be heated to 60C. Every time the sample

is taken to laboratory tests, viscosity will be measured at 60C. It should
not be more than 45cp 10%. A new resin will be at 15cp. A new resin
and hardener mixture is to be added if the viscosity is more.

In this process, the resin filling in the vessels and taking back to
the resin tanks is done by the pressure difference inside and outside of the
chamber. The impregnation vessel is filled with resin by pressure
difference. The resin in the resin tank is at atmospheric level and the
chamber is maintained at 0.2mbar pressure. The resin flows from higher
pressure to lower pressure. So, no pumps are required to fill the resin in
to the impregnating vessel. The resin filling will be completed in 25-30
minutes. During this time there is a change in pressure inside the
chamber. This should not be less than 0.06 mbar. If it is less than
0.06mbar, the vacuum will be created in the chamber up to 0.2mbar.

The level of the resin in the impregnating vessel should be 100mm

above the job. This can be seen through mirrors arranged above the
chamber. Otherwise, there is a control and record of this resin in the
control room.

PRESSURE CYCLE:

After filling the resin in the impregnating vessel up to 100mm

above the job, the Resin is to be allowed to settle for 10-15 minutes. The
total job is flooded with epoxy resin with a hydrostatic pressure of the
resin. Only surface of the insulation can be filled with resin. To have an
effective penetration up to the end of the copper barrier, pressure is to be
created to 4bar. It could be maintained constantly for 4 hours.

RESIN PUMPING BACK TO RESIN TANK:

The resin is pressurized as per the pressure cycle, by which the
opening of the valves will allow the resin to combine to the storage tank.
The job also shall be allowed to dry for about 10 minutes.
ACCELERATOR SPRAY:

After allowing for dripping, the job is taken outside from the tank
and arrangements are to be made for accelerator spray on job. Accelerator
is similar to catalyst in polymerization process. Due to polymerization
between resin and hardener, the total mass becomes hard. The accelerator
spray consists of following ratio:

1. Epoxy Resin E1023 1.0 parts

2. Hardener H1006 1.4 parts
3. Epoxy Resin E1025.1 0.5 parts
4. Hardener H1001 1.0 parts
5. Trichloro Ethylene 1.0 parts

In BHEL, they are using

 Epoxy Resin MY 790 1.0 parts
 Hardener HY1102BD 1.0 parts

It is manufactured by M/S CIBA Company, SWITZERLAND.

POST CURING:

After completion of all the above operations, the job is to be post

cured. The process of post curing is carried out at 140C for duration of
20 hours in order to avoid the unpolymerised Resin.

QUALITY CHECKS ON RESIN MIXTURE IN RESIN

POOR PROCESS:

The Resin mixture is a combination of epoxy Resin and hardener.

The containers of resin and hardener are placed in cool, dry place. They
are closed until processing for protecting against humidity. The
impregnating resin mixture is in the ratio of 100 parts of Epoxy resin to
100 parts of Hardener in a resin tank of the impregnation unit. The epoxy
resin and hardener are heated in an oven at 125C and sample is taken
from every drum to test before release. The resin mixture is sensitive to
moisture and therefore it is stored under vacuum below 20C but chilled
not below 8C. After thorough mixing, the Resin mixture is tested.

TESTS ON RESIN MIXTURE:

Before beginning impregnation and after a stand still period of

more than 5 days, the resin mixture is tested in the following manner.

1) The resin mixture is tested for it’s viscosity at 60C and limiting
value of viscosity is 50m poise above which the resin is rejected.

2) The resin again tested for the increase in its viscosity at 60C after 20
hours. Heating at 100 degrees centigrade, the maximum value at this
point is 9m poise.

3) The resin again tested for it’s saponification number, whose specified
Value is 33113 MgKOH/gram.

4) After this is tested for the ester number, which is difference between
saponification number and total acid number. Its maximum limiting value
is 10. In case it exceeds 10 necessary addition to resin or hardener is
done. According saponification number the resin mixture is released after
each test for use.

TESTING PERFORMANCE OF RESIN POOR SYSTEM:

BEFORE IMPREGNATION PROCESS:

The different tests which are carried out after laying the bars in the
stator slots. They are:
1. Complete bottom layer high voltage test.
2. Complete top layer high voltage test.
3. Winding resistance measurement.

In addition to these above-mentioned tests they carry some other

tests, they are:

1. A.C High voltage test.

2. Mechanical Run test.

1. BOTTOM LAYER TEST:

After laying the bottom bars high voltage test is conducted with
1.15 Up for 1 minute. Where Up=2Un+1, Up-Final test voltage Un-
Rated voltage of generator.

2. TOP LAYER TEST:

After laying the top bars high voltage test is conducted with 1.1 Up
for 1 minute, where Up=2Un+1, Up-Final test voltage Un-Rated voltage
generator.

3. INTER CONNECTION CHECKING:

After completion of connecting, Winding and baking High voltage is

conducted with 1.05 Up for 1 minute. When one phase is under testing,
the other phases are earthen measurement of resistance of individual
phases give the checking of interconnection.

4. A.C HIGH VOLTAGE TEST:

After laying the top and bottom bars high voltage test with A.C is
carried out by connecting all other phases to ground.

5. MECHANICAL RUN TEST:

 Dynamic test is carried out to find various losses, they are
1. Mechanical losses.
2. Iron losses.
3. Copper losses.

TESTS ON VPI SYSTEM:

AFTER IMPREGNATION:

After impregnation of the stator core by VPI process the following

tests are conducted.
1) TAN § test
2) High Voltage A.C test.

TAN § TEST:

After impregnation and curing of the winding a dissipation factor

Vs voltage measurement as stipulated in the applicable national and
international standard specification is performed for each bar between all
individual phase windings to ground.

Guiding values for the dissipation factor and its rise with the
voltage merely given in the KEMA specifications. According to these
specifications, the maximum value shall not exceed 0.001 at 20% of rated
voltage and 0.008 per 20% of rated voltage up to a rated voltage.
Windings manufactured by the vacuum pressure impregnation process
comply with these limits.

The above test results are specified in the following graphs. First
graph shows that voltage Vs tan curve, it shows different tan values at
different percentage of rated voltage 20%, 40%, 60%, 80%, 100% of
rated voltage respectively.

The second graph is a electric field Vs Life of Insulation material.

It shows that resin poor system of insulation has very long life compared
to resin rich insulation. At 10 KV the resin poor system insulation has a
lifetime of 849 years. Any good machine has life span of 25-30 years. By
using this insulation we will get a very long life withstandable machine.

High voltage AC Test

AC High voltage test is conducted on VPI system after impregnation

to verify proper impregnation and dielectric strength of insulation. This
test was conducted at 105% of winding test voltage i.e. Up=2Un+1 KV
Where Up-winding test voltage
Un-Rated voltage of machine

Advantages of Resin poor system of Insulation:

1.It has got better Dielectric strength

2.Heat transfer coefficient is much better.

3.Maintainance free and core and frame are independent

4.It gives better capacitance resulting in less dielectric losses due to

which the insulation life will be more.

5.The cost will be less and it is latest technology.

6.Reduction in time cycle and consumption for MW also less and it gives
high quality.

Disadvantages

1.If any short circuit is noticed, the repairing process is difficult and need
of excess resin from outside.

2.Dependability for basic insulation materials on foreign supply.

 CONCLUSION:

Considering the manifold advantages of VPI system of

insulation of stator winding the leading manufactures of world are going
to adopt this system for generators up to 400 MW with Hydrogen gas
cooling. BHEL has plans to fall in the line of state of Hydrogen gas
cooling. BHEL has plans to fall in the line of state of the art technology.
However as the size of generator for VPI system increases there will be
need to store more amount of resin. The reliability of the generators with
this insulation system favors its use, due to better thermal, electrical,
mechanical and chemical life.

In view of the above, in the coming decades the Indian grids will
use more of such generators in operation. In the scenario of world
market, which demands generators with less cost at the best possible
tome with better reliability, VPI system of insulation will provide most
viable solution.