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A comprehensive report on the study of

Manufacture & Assembly of Turbo Generator
Project Incharge:- Supervised By:- Submitted

By:-
Mr. Raj Singh Mr. Satish k.Singh Rahul Vijay

HRDC , Engineer,BL-1, Branch-ELE
BHEL ,Haridwar THRI
ACKNOWLEDGEMENT
Engineer is a boon for this modern era because of leaps and bound
advancement in modern technology. So it is a very important to impart
a practical knowledge and theoretical knowledge. I am very grateful
that I got the opportunity to have training from BHEL, Haridwar.
Which is the no.1 industry in India.
Special thanks to Mr. Satish K. Singh for providing me with an

opportunity to undergo training under his able guidance and offering
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1/29/14 amit_bhel - Copy.docx
me a very deep knowledge of practice aspect of industrial work

culture.
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.
CONTENTS
1. Introduction
2. Coil & insulation manufacturing shop (block-4)
3. Electrical machine block (Block-1)
4. Manufacturing process of turbo generator
5. Introduction to 500MW Turbo Generator
6. Constructional features of stator body
7. Constructional features of core
8. Constructional features of Winding
9. Constructional features of Rotor
10-Working principle
11-Cooling system
12-Excitation system
13-Electrical generator protection
14-Conclusion
INTRODUCTION:-
BHEL is the largest engineering and manufacturing enterprise in India
in the energy-related/infrastructure sector, today. BHEL was
established more than 40 years ago, ushering in the indigenous Heavy
Electrical Equipment industry in India - a dream that has been more
than realized with a well-recognized track record of performance. The
company has been earning profits continuously since 1971-72 and
paying dividends since 1976-77.BHEL manufactures over 180
products under 30 major product groups and caters to core sectors of
the Indian Economy viz., Power Generation & Transmission, Industry,
Transportation, Telecommunication, Renewable Energy, etc. The wide
network of BHEL's 14 manufacturing divisions, four Power Sector
regional centre, over 100 project sites, eight service centre and 18
regional offices, enables the Company to promptly serve its customers
and provide them with suitable products, systems and services.
Efficiently and at competitive prices. The high level of quality&
reliability of its products is due to the emphasis on design, engineering
and manufacturing to international standards by acquiring and
adapting some of the best technologies from leading companies in the
world, together with technologies developed in its own R&D centre,
BHEL has
•Installed equipment for over 90,000 MW of power generation for
Utilities, Captive and Industrial users.
•Supplied over 2,25,000 MVA transformer capacity and other
equipment operating in Transmission & Distribution network up to
400 kV (AC & DC).
•Supplied over 25,000 Motors with Drive Control System to Power
projects, Petrochemicals, Refineries, Steel, Aluminum, Fertilizer,
Cement plants, etc.
•Supplied Traction electrics and AC/DC locos to power over 12,000
km Railway network.
•Supplied over one million Valves to Power Plants and other Industries
HEEP
HEEP is also known as heavy electrical equipment plant. In this plant
the electrical devices is manufacture for the production of the Turbo
Generator. In HEEP plant we produce turbo generator, exciter,
turbine, AC/DC motor, etc. HEEP had started the production from
January 1967. More than 40% of the electrical energy is generated
from the power equipment supplied by BHEL, Haridwar.
COIL & INSULATION MANUFACTURING AHOP (BLOCK-

4):-
BAY-1: Bar winding shop manufacturing of stator winding of

generator.
BAY-2: manufacturing of heavy duty generator stator bars with new
CNC machine No. 3-464 i.e. Robol bar centre.
BAY-3: Insulation detail shop. Manufacturing of hard insulation &
machining of hard insulation part (Glass textolite) such as packing
washer, insulation box, wedges etc.
Bar Shop: This shop is meant for manufacturing of stator winding coil
of turbo generator.
Why do we call it bar:-

It is quite difficult of manufacture, handle and wind in the stator slot
of the generator of higher generation capacity because, of its bigger
size and heavy weight. That is why we make coil in two parts. One
part its bottom part of coil called bottom or lower bar and other part of
coil is called top bar or upper bar.
Turbo – generator: The manufacturing of bars of standard capacity
such as:
100MW, 130MW, 150MW, 210/235MW, 210/250MW, 500MW,
600MW
TYPES OF GENERATOR:
The generator may be classified as based upon the cooling system
used in the generators such as: THRI, TARI, THDI, THDD, THDF,
THFF, THW.
T= First alphabet significance the type of generator i.e. turbo
generator of hydro- generator.
H/A= Second alphabet stands for the cooling media used for the
cooling of rotor i.e. hydrogen gas or air.
R/D/F/I= Third alphabet significance cooling of rotor e.g. radial,
indirect forced, direct etc.
I/D/F= Last alphabet stands for the type of cooling if stator e.g.
indirect cooling, direct cooling, forced cooling.
W= Cooling media used for cooling of stator coil e.g. water
MANUFACTURING PROCESS OF BARS:
Some points in manufacturing process are given below:-
Conductor Cleaning:-
In this process conductor is made to clean and straight by some
process such that it can be used for further process.
Conductor Cutting:-
This process is done by automatic CNC machine. In this process the

pre insulated copper conductor is cut into number of pieces of
required length (length given in drawing as per design).Insulation is
removed from both side of copper conductor out.
Transposition of conductor:-
Transposition is mainly reqired to reduce eddy current loses.
Transposition means changing/shifting of position of each conductor in
active core (slot) part .After cutting the required number of
conductors the conductors are arranged in the comb in staggered
manner and then bend are given to the conductors with the help of
bending die at required distance as shown in figure . Then the
conductor are taken out from the comb and die and placed with their
end with the line and transposition is carried out. This process is
repeated for making another half of the bar which could be mirror of
the first half. The two halves of the bars are overlapped over each
other and a spacer is placed between the two halves.
CrossOver Insulation:-
Flige tap is used to prevent from sparking in between transpositioned
conductors of one bar as shown in figure .MICA insulation is used
over bar to protect from sparking.The pre insulation of the copper
conductor may get damaged due to mechanical bending in die during
transposition , hence the insulation spacers are provided at the
crossover position of the conductors . A filler material (insulating
putty of moulding mecanite ) is provided along the height of the bars
to maintain the rectangular shape and to cover the difference of the
level of conductors.
Stack Consolidation(pressing):
The core part of the bar is pressed in press (closed box) under pressure
(varies from product to product) and temperature of 160`C for a given
period. The consolidated stack is withdrawn from the press and the
dimensions are checked.
Inter Strand Short test:
The consolidation bar stack is tested for the short between any two
conductor in the bar, if found then it has to be rectified .Dark lamp
method is used .
Forming:
The straight bar is stack is formed as per overhang profile (as per
design). The overhang portion is consolidated after forming.
The straight bar stack is bend at the two end portion as per
requirement design
Contact Slew & Bottem:-
Contact slew is made up of copper . It is used to short circuit
two bars to make one coil.Lower end of one bar is connected to the
lower end of another bar & upper parts of two bars are connected
with contact slew .Bottem is used to provide strength . Contact slew is
also used for cooling
Brazing of coil lugs:
For water cooled generator bars, the electrical connection contact
water box for inlet and outlet of water are brazed. The water box is
also known as contact slew. The contact slew is brazed with the help
of copper aluminium alloy rod. This rod is brought to touch to hot
contact slew and after melting it fill the spaced, in this manner the bar
is brazed.
Nitrogen leak test:
The bar is tested for nitrogen flow test, nitrogen leak test and pressure
test for given duration.

Thermal Shock Test:
In thermal shock test the 23 cycle of hot and cold water are flew
throw the bar to ensure the thermal expansion and contraction of
joints. The temperature of hot water is about 80`C and the cold water
is 30`C. By doing this test if there is any fracture or voids at the joints
are present , then it exposed and easily detected.
Helium leakage test:
This test is performed after the thermal shock test. With the help of
this test we can found very minute leakage if present. In this test the
helium gas pipe is connected at one end and the other end is closed.
After this we insert a helium spectrometer to measure the pressure of
the helium gas.
Impregnation and baking:
Thermo reactive or rich resin system:
In case of rich resin insulation the bar is pressed in closed box in

heated condition and baked under pressure and temperature as per
requirement for a given period.
In this type of insulation system the bond content in resin is 35-37%.
The raw material are ready to use and required preservation and
working on temperature 20-25C. Its shelf life is one year when kept on
temperature 20C which could be increased when kept at temperature
of 5C.
Micalastic or poor resin system :

In case of poor resin system the insulated bars are heated under
vacuum and the impregnated (dipped) in heated resin so that all the air
gap are filled, layer by layer, with resin. Then extra resin is drained out
and the bar are heated and baked under pressed condition in closed
fixture.
In this type of insulation the bond content in the resin is 5-7%
and insulating material is prepared with accelerator treatment.
The temperature control need not required. The insulating
material is applied on job and then the same is impregnated in
the resin.
VPI Mecalasti System :
The bar already laid in closed fixture and full fixture is impregnated
(dipped) in resin and then fixture with box is baked under given
temperature for given duration.
VIP Micalastic system :
The individual (separate) bar is heated in vacuum and impregnated in

resin. Then bar is taken out and pressed in closed box fixture and then
baked at given temperature for given duration.
Insulation:
The bar is insulated with the given number of layer to built the wall
thickness of insulation subject to the generating voltage of machine.
Finishing:
At the edges surface area is smaller so the air gap contact is smaller
therefor reluctance is greater so the potential graidient is maximum at
the edges so more chance of sparking at the edges . So to make
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uniform potential gradient finishing is required at the surface . The

baked and dimensionally correct bars are sanded-off to smoothen the
edges and the surface is calibrated, if required, for the dimension .
Conducting varnish coating:
OCP (Outer Corona Protection) Coating:

The black semiconducting varnish coating is applied on the bar surface
on core length.
ECP (End Corona Protection) Coating:
The gray semiconducting varnish is applied on the bend outside

corona end of bars in gradient to prevent from discharge and minimize
the end corona.
Testing:
Tan0 Test:
This test is carried out to insure the healthiness of dielectric
(Insulation) i.e. dense or rare and measure the capacitance loss.
H.V. Test:
Each bar is tested momentary at high voltage increased gradually to
three times higher than rated voltage.
Dispatched for winding:
The bars preserved with polythene sleeves to protect from dust, oil,
rain etc are send to block-1 for winding.
ELECTRICAL MACHINE (BLCOK-1):–
INTRODUCTION:-
1. Block first is design to manufacture Turbo Generators.
2. The block consist of 4 bays-Bay 1(36*482meters), Bay-2(36*360
meters), and Bay-3 & Bay-4(of size 24*360 meters each).
3. Testing facilities of turbo generator are available in Bay-2
4. There is a special test bed area for testing of T.G. of capacity of
500MW unit sizes.
MANUFACTURING PROCESS OF TURBO GENERATOR:-
Fabricated components are received in respective machine sections
from-
Fabrications blocks (block-2,5, 6, 8), while castings and
forgings are received from sister unit CFFP and other indigenous and
foreign sources for turbo generators. Stampings are received from
stampings manufacture block, block-4and coils bars, insulating details
and sheet.
Metal components are received from coils and insulation manufacture
and apparatus and control gear box (Blok-4).
TURBO GENERATOR:-
The turbo-generator is common-shaft excitation AC synchronous
generator with 3phases, 2 poles or with 3 phases, 4 poles.
BHEL-Hyderabad makes turbo generators
that have the brushless excitation mechanism which has been
explained in the NTPC report. BHEL presently has manufactured
Turbo-Generators of ratings up to 560 MW and is in the process of
going up to 660 MW. It has also the capability to take up the
manufacture of ratings up to 1000 MW suitable for thermal power

generation, gas based and combined cycle power generation as-well-as
for diverse industrial applications like Paper, Sugar, Cement,
Petrochemical, Fertilizers, Rayon Industries, etc.
500MW turbo generator at a glance-

2-pole machine with the following features:-
1. Direct cooling of stator winding with water.
2. Direct hydrogen cooling for rotor.
3. Micalastic insulation system.
4. Spring mounted core housing for effective transmission of
vibration.
5. Brushless excitation system.
6. Vertical hydrogen coolers.
Salient technical data-
1. Rated output :588MVA, 500MW
2. Terminal voltage :21KV
3. Rated stator current: 16KA
4. Rated frequency :50Hz
5. Rated power factor: 0.85 lag
6. Efficiency : 98.55%
Manufacturing process:-
1- Stator-
The stator is assembled as six parts. It is made up of steel with 4.5% of
silica. Silica decreases hysteresis loss. The sheets are cut at 30 degree
angles. The sheets then are punched with man drill holes, support rod
slots and slots for the conductors. This process is called notching and
the cutting part as shearing. The sheets are then varnished after
blanking or smoothening of the surface. This is to increase the
insulation. A bunch of these sheets are stacked together and
compressed onto each other so that air gaps are eliminated. These
stacks are then assembled with a small air gap differentiating each
stack. This ventilates the machine and keeps it cool. After the
assembly of the stator shell, the inside of the slots are varnished. The
sheets of the core are varnished with xylor, at a temperature of 30-400
degrees Celsius. It is heated, coated then cooled. After the core is
assembled , the winding is placed in the stator. The winding type
depends upon the power required and the current required to be
produced. The core and the winding are separated by an insulation
called HGL. This prevents the shorting of the core and winding .The
winding in the front and back are also separated by this material and
they are joined as per the winding required (lap or wave) using glass-
o-flex, a pink ribbon like material. The windings are insulated. These
windings are then painted to obtain a the stator, where the power is
generated. The windings are always inserted from the exciter end, one
is clockwise and the other anti-clockwise.
2-The 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
The rotor is carved out with the slots into a cylindrical shape from a
large block of metal using Lathe heavy machines. The rotor consists of
2 ends –
•The turbine coupling end
•The exciter end
The turbine end has a coupling shaft which is circular in shape and has
slots.
The exciter end has an input lead and an output lead which are used to
give the rotor DC input for the excitation of the rotating field.
The ends of each rotor consist of bearings. These bearings are placed
so as to support the shaft. The bearing consists of oil which is used to
support a thin film over the surface. This lubricates and decreases
friction and losses. The bearing has top end and bottom end and is
stationary. The top end is used to supply the oil. After the
construction, the winding is fitted into the slots. The slots and windings
are separated by HGL or hard glass lamination which insulates the
core from the cable. The rotor is constructed so as to obtain brushless
excitation. The complete rotor along with the excitation mechanism is
mounted on the shaft and is balanced for synchronous speed. For
better balancing weight removal is done as that is a better option to
adding weight to the system. The rotor ends are provided with
induction motor fans which are used for cooling of the rotor winding.
The winding is made up of 99.99 % copper.
WORKING PRINCIPLE:-
One end of the alternator is coupled to the turbine and other end is
coupled through the exciter. The whole assembly is on the shaft.
Turbine act as a prime mover, the permanent magnet of the exciter
creates a permanent magnetic field, which is cut by the rotor
conductors. Making the formation of 3-phase power, this 3-phase
power is fed to the thyristor controlled switches for rectification. The
3-phase power is fed to main exciter, after that this 3-phase power is
given to the diode wheel so it is produce the dc power. The dc power
is given to the main alternator field without brushes and slip ring. Then
alternating field is produce by the cut of rotor conductors making the
production of emf by the FARADAY’S LAW.
Cooling of the Alternator:-

The machine needs to be cooled to avoid damage and for greater life.
Heating causes insulation failure. Hence, cooling is a very important
factor that needs to be taken care of. For cooling, the stator and rotor
are provided with a ventilation to cool it down. Air gaps are provided
throughout the machine. But for very high power machines
natural cooling is insufficient so a cooling system is provided. For
collection of hot air, a large chamber is provided. This air is cooled
and recycled into the generator. The rotor of the alternator consists of
fans powered by induction motors. They suck in the air and push it
through to the cooling chamber. Another method is also used which is
called hydrogen cooling. Hydrogen acts as ac coolant and the chamber
is shut completely is filled with hydrogen. Hydrogen cools itself. The
chamber is emptied each time the machine is stopped.
TG TEST BED:-
New LSTG [Large Scale Turbo Generator] TEST BED has been put
up with indigenous know –how in record time testing Turbo Generator
of rating 500MW and above up to 1000MW. It caters to the most
advanced requirement of testing by employing on line computer for
data analysis.
Circuit –Breakers:-
Current interruption in a high-voltage circuit-breaker is obtained by
separating two contacts in a medium, such as SF6, having excellent
dielectric and arc quenching properties. After contact separation,
current is carried through an arc and is interrupted when this arc is
cooled by a gas blast of sufficient intensity. Gas blast applied on the
arc must be able to cool it rapidly so that gas temperature between the
contacts is reduced from 20,000 K to less than 2000 K in a few
hundred microseconds, so that it is able to withstand the transient
recovery voltage that is applied across the contacts after current
interruption. Sulphur hexa fluoride is generally used in present high-
voltage circuit-breakers (of rated voltage higher than52 kV)In arc
assisted opening interruption principle arc energy is used, on the one
hand to generate the blast by thermal expansion and, on the other
hand, to accelerate the moving part of the circuit breaker when
interrupting high currents. The over pressure produced by the arc
energy downstream of the interruption zone is applied on an auxiliary
piston linked with the moving part. The resulting force accelerates the
moving part, thus increasing the energy available for tripping.
With this interrupting principle it is possible, during high-current

interruptions, to increase by about 30% the tripping energy delivered

by the operating mechanism and to maintain the opening speed
independently of the current. It is obviously better suited to circuit-
breakers with high breaking currents such as Generator circuit-
breaker.
COOLING SYSTEM:-
Cooling system is a very important part of the alternator. Mainly two

types of cooling process is occur such as-
1. Radial cooling
2. Axial cooling
Since the cooling system is divided three part such as-
1. Hydrogen cooling
2. Water cooling
3. Air cooling
Cooling system is used because dissipating the heat generated by

various losses and to prolong the life of insulating material. In small
generator natural cooling is adequate. In these machines cooling by
natural sources is sufficient, but in large generators natural cooling
is in sufficient, so in these generator air, water &hydrogen is done.
Force air cooling is used for large machine. In this scheme air is first
passed through cleaning filter and then forced through the machine
for cooling purpose. Air cooling system is better and necessary in
500MW & 600MW generator.
EXCITATION SYSTEM:-
Turbo generator is a doubly excited machine. Because it’s field
winding is excited by dc source and it’s armature winding is
connected to ac source. For dc excitation we need use the use of
exciter. Hence there are three types of dc excitation-
1. DC exciter
2. Static excitation
3. Brushless exciter
In our BHEL organization brushless exciter is widely use because

slip ring and brushes is absent and it is provide less losses so that it’s
efficiency is high so we use the brushless exciter. The brushless
exciter is used for generating the dc field which is used to fall on
alternator of rotor. When the dc field is fall on the rotor and the
rotor is directly connected to the turbine so that the turbine is rotate
the rotor, the alternating field is generated by the rotor then due to
the induction the alternating emf is generated in the stator core.
These emf is received by the stator terminal those are called ac
voltage.
The brushless exciter has mainly two parts such has-
1. Pilot exciter
2. Main exciter
In pilot exciter permanent magnet is used, which produce the

permanent magnetic field. Three phase power from pilot exciter is

fed to thyristor controlled bridge to main exciter. After
rectification the controlled dc output is supplied to stationary field
winding of main exciter.Three phase power from main exciter is fed
to bridge
Rectifier to get dc power which is fed to field winding of alternator.
ELECTRICAL GENERATOR PROTECTION:-
Generator may be endangered by short circuit, ground fault, over
voltage, under excitation and excessive thermal stresses. The
following protective equipment is recommended such as –
1. 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
CONCLUSION:-
Bharat heavy electrical limited is the largest engineering and

manufacturing enterprises of kind in the public sector in India. The
sector is an important part in turbo generators. The stator is
assembled by the laminated sheets. We use the UNIVERSAL

FORM FICTURE type bar which assemble all the straight part and
the over hang at a time. The universal from facture type bar is more
flexible and its life time more. We use the bar transposition for
stator winding which is more advantages. BHEL has acquired the
latest technology in the insulation system, the VACCUM
IMPREGINATION system of insulation, which has various
advantages like cost reduction with improve quality. Thus designed
an manufactured start of turbo generator is used mostly in paper,
sugar, cement, petrochemical, fertilizer, Rayon, industries. The
architecture of BHEL, 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 has allowed us and an opportunity to get and
exposure implementation of theoretical fundamental.

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1/29/14 amit_bhel - Copy.

A comprehensive report on the study of

Project Incharge:- Supervised By:- Submitted

Mr. Raj Singh Mr. Satish k.Singh Rahul Vijay

Special thanks to Mr. Satish K. Singh for providing me with an

me a very deep knowledge of practice aspect of industrial work

I express my sincere thanks and gratitude to BHEL authorities for

COIL & INSULATION MANUFACTURING AHOP (BLOCK-

BAY-1: Bar winding shop manufacturing of stator winding of

Why do we call it bar:-

This process is done by automatic CNC machine. In this process the

test for given duration.

Impregnation and baking:

Thermo reactive or rich resin system:

In case of rich resin insulation the bar is pressed in closed box in

Micalastic or poor resin system :

VPI Mecalasti System :

VIP Micalastic system :

The individual (separate) bar is heated in vacuum and impregnated in

uniform potential gradient finishing is required at the surface . The

Conducting varnish coating:

OCP (Outer Corona Protection) Coating:

ECP (End Corona Protection) Coating:

The gray semiconducting varnish is applied on the bend outside

ELECTRICAL MACHINE (BLCOK-1):–

manufacture of ratings up to 1000 MW suitable for thermal power

500MW turbo generator at a glance-

Cooling of the Alternator:-

With this interrupting principle it is possible, during high-current

interruptions, to increase by about 30% the tripping energy delivered

Cooling system is a very important part of the alternator. Mainly two

Cooling system is used because dissipating the heat generated by

In our BHEL organization brushless exciter is widely use because

In pilot exciter permanent magnet is used, which produce the

permanent magnetic field. Three phase power from pilot exciter is

Bharat heavy electrical limited is the largest engineering and

assembled by the laminated sheets. We use the UNIVERSAL

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