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. Satish Kumar Sir 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.

CONTENT
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

OBJECTIVE
The goal of this report was to study of basic knowledge of
turbo generator.

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.

BHELS UNIT IN INDIA

S.No.

PLACE
UNITS

1.

HARIDWAR

2.

BHOPAL

3.

JHANSI

4.

JAGDISHPUR

5.

HYDERABAD

6.

BANGALORE

(PLANTS)

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. Custommade 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.
5

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-theart 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 BHEL 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
6

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 battery-powered
road vehicles. The company has taken up R&D efforts for
development of multi-junction amorphous solar cells and fuel cells
based systems.

BHEL HARIDWAR
At the foothills of the majestic Himalayas & on the banks of a holy
Gangesin 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
7

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 (T.G.) 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.

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.
2.
3.
4.
5.

THRI
TARI
THDI
THDD
THDF
6. THFF
9

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

10

COMPONENTS OF T.G. -

STATOR

Stator frame
Stator core
Stator winding
End covers
ROTOR
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.

11

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
12

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 short13

circuiting. To monitor the formation of hot spots resistance

transducer are placed along the bottom of slots. To ensure that
core losses are within limits and there are no hot spots present in
the core. The core loss test is done after completion of core
assembly.

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
14

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.

15

INSULATION OF BARS
Vacuum pressedimpregnated mica elastichighvoltageinsulation:

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.
Coronaprotection:
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.
16

Resistancetemperaturedetector :
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.

17

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.

18

19

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
20

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

21

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
22

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
23

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. The shrunk
slot of current. To reduce the stray losses and have high strength,
the rings are made up of non- magnetic 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
24

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
25

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
26

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
27

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

28

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
29

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
30

in the conducting material of stator and rotor.

Test procedure for measurement of impedance of rotor winding
with 50 hertz supply

31

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)
Multi meter
Current transformer (50/5 A)
Connecting leads

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 LIMITIMPEDENCE 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.

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PURPOSE
a. To determine total leakage reactance Xl.
b. To determine core leakage reactance Xc.
c. 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.
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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.

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CONCLUSION

Training at B.H.E.L. has proved to be quite faithful. It

proved an opportunity for encounter with such huge machine like
turbo-generators.

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.
However, training has proved to be satisfactory. It has allowed us an
opportunity to get an exposure of the practical implementation of theoretical
fundamentals.

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References

B.H.E.L. MANUALS
B.H.E.L. Websites
Electrical machines P.S. BIMBHRA
Electrical machine design ebook on google
Internet resource from Wikipedia

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