Documente Academic
Documente Profesional
Documente Cultură
PROCESS OF
TURBO GENERATORS
.…………………………………………………………………………
MANUFACTURING PROCESS OF TURBO
GENERATORS
A Mini Project Work
BACHELOR OF TECHNOLOGY
In
Ms. PARVATHI
Assistant Professor
We take this opportunity to record our gratitude to all those who helped us in
successful completion of the project.
We wish to express our deep sense of gratitude to our Internal Guide Ms.
PARVATHI for her able guidance and useful suggestions, which helped us in
completing the project work in time.
Finally, we wish to express our profound thanks to all the employees, in charges
and workmen without whose support, completion of this project would have been
impossible.
ABSTRACT
Chapter 1…………………………………………………………….1-2
Chapter 2…………………………………………………………….3-4
2. Introduction
2.4 Synchronous generators classification based on the medium used for generation
2.5.1 Stator
2.5.2 Insulation
2.5.3 Rotor
Chapter 3……………………………………………………………..5-14
3. Stator
3.7.2 RTD’s
Chapter 4………………………………………………………………….14-15
4. Assemble of windings
Chapter 5…………………………………………………………………..16-17
5. Insulation system
5.1 BHEL insulation system for Turbo Generators
Chapter 6……………………………………………………………….18-22
6. VPI system
1. General
2. Preheating
3. Impregnation
4. Post curing
5. Electrical testing
Chapter 7…………………………………………………………………..23-27
7. Rotor
7.2.1 Construction
7.2.3 Insulation
8. Bearings
Excitation system
Chapter 10……………………………………………………………….30-33
Testing
10.6 HV test
Chapter 11………………………………………………………………….34
REFERENCES……………………………………………………………….35
ABOUT THE COMPANY: BHARAT HEAVY ELECTRICALS
LIMITED
CHAPTER 1
ABOUT THE COMPANY: BHARAT HEAVY ELECTRICALS LIMITED
Gas turbines
Steam turbines
Compressors
Turbo generators
Heat Exchangers
Pumps
Pulverizers
Switch Gears
Oil rigs
BHEL Hyderabad is the only one in Asia that has the latest type of insulation system called the
Vacuum Pressure Impregnation System.
INTRODUCTION
CHAPTER 2
2. INTRODUCTION:
• salient rotor
2.5.1 STATOR
Stator Frame
Stator Core
Stator Windings
End Covers
2.5.2 INSULATION
2.5.3 ROTOR
Rotor Shaft
Rotor Windings
Bearings
Cooling System
Excitation System
STATOR
CHAPTER 3
3. STATOR
Stator winding is the one which induces emf and supplies the load. Stator winding is placed
in the slots of stator core. Due to the advantages of generation and utilization of 3 phase power
we use three phase windings for generation. So number of slots must be a multiple of 3 (or 6 if
two parallel circuits are required).
Generally two layer lap winding, chorded to about 5/6 pitch which practically eliminates 5th
and 7th harmonics from the flux wage or open circuit induced emf wave is used. The stator coil is
made up of number of strips instead of single solid piece to reduce the skin effect.
Generally diamond pulled multiturn coils are used for low capacity machine. In this coils are
pulled in a particular shape similar as diamond that’s why they are called so.
In large capacity machines we use ROEBEL bars. These coils were constructed after
considering the skin effect losses. In the straight slot portion, the conductors or strips are
transposed by 360 degrees. The transposition is done to ensure that all the strips occupy equal
length under similar conditions of the flux. High purity (99%) copper conductors/strips are
used to make the coils. This results in high strength properties at higher temperatures so that
deformations due to the thermal stresses are eliminated. The high voltage insulation is provided
according to the resin poor mica base of thermosetting epoxy system. Several half overlapped
continuous layers of resin poor mica tape are applied over the bars. The thickness of the tape
depends on the machine voltage.
Slot discharges occur if there are gaps within the slot between the surface of the insulation and
that of the core. This may cause ionization of he air in the gap, due to breakdown of the air at the
instances of voltage distribution between the copper conductor and the iron.
Within the slots, the outer surface of the conductor insulation is at earth potential, in the
overhanging it will approach more nearly to the potential of the enclosed copper. Surface
discharge will take place if the potential gradient at the transition from slot to overhang is
excessive, and it is usually necessary to introduce voltage grading by means of a semi-
conducting (graphite) surface layer, extending a short distance outward from the slot ends.
3.6.2 MANUFACTURE OF STATOR COILS:
1.Tape the bar with Resin poor fine mica paper tape on straight part of bar taking copper foil
outside the tape.
3.Tape the straight part of bar with conductive polyester fleece tape with starting and ending
shall be on straight part of bar.
4.Tape with mica splitting tape with accelerator taking Ocp layer into and leaving.
5.Tape the straight part of bar with polyester Conductive fleece tape.
The stator end covers are attached to end flanges of stator frame and also rest on the foundation
plate. The end covers are made up of non-magnetic material (Aluminium castings) to reduce
stray load and eddy current losses.
The phase connectors consist of flat copper sections, which results in low specific current
loading. The phase connectors are wrapped with resin rich mica tape. After curing the
connectors are attached to the pressure plate with clamps and bolts.
The temperature measurements on the generator are made with RTDs. They are placed at various
sections of the core and winding. When making measurements with RTDs the resistance element
is exposed to the temperature to be measured.
The RTD works on the principle of the change in electrical resistance of a conductor due to
temperature. R= Ro (1+ α T) ;Where Ro = reference resistance at room temperature; R=
temperature coefficient of resistance ; T = temperature difference in C.
ASSEMBLE OF WINDINGS
CHAPTER 4
Assemble the HG rings on the both the side, turbine side as well as laminated side. Pass HGL
gauge in all the slots to detect laminations projection of the bottom surface if any lamination
projection are noticed then rectify the projection. Check prior operation completion.
Identify all the RTD slots with respect to the drawing and assemble the RTD slots as per the
drawing purposes required. Identify all the slots with slots number as per the drawing.
Each individual bars subjected for pressing at 60 kg/cm2 horizontal & vertical in order to
obtain predetermine the dimensions up to 30 minutes.
This process is carried out for all the bottom bars before laying to the respective slots.
By following above procedure first bar is layed in to the respective slots when the bar is
center to the core centre by measuring pitch dimensions on both sides.
Similarly next bar is layed in to the respective bar by following procedure.
After laying the every two bars the over hangs are reinforced with glass mat at three
different locations on both sides and tying the bars with neoprene glass view.
Similarly the above procedure is following for all the eliminating bars.
After completion bottom bars laying the bars reinforced end wedges and middle wedges.
Then the bottom bars are subjected to D.C high voltage.
4.2.2 Inter layer inserts & RTD’S assembles: All the inter layer inserts & RTD’S are
assembled as per drawing required i.e. inter layer inserts are assembled in each and every slots
except RTD’S slots. In RTD’S slots only RTD’S are assembled before laying top bars.
Stiffner are assembled on the winding layers on to the bottom bars by reinforcing & placing glass
mat and tieing with neipring glass. Stiffeners’ are carried out on the both sides.
Each individual top bar is subjected to pressure 60kg/cm2 horizontally and vertically for
duration of 30minutes in order to obtain pre determine dimensions.
The above operation for each top bar before laying in to their respective slots.
First top bar laying is carried out by centering the bar with respect to the stator core &
check the pitch dimensions on both sides.
Similarly the next bar is assembled in to respective slots by following the above
procedure.
After laying every two bars the over hangs are reinforced by inserting glass mat at 3
different locations on the both sides.
By following the above procedure all the top bars are layed in to the slots by full filling
the drawing requirements then the top bars are reinforced wedging with HGW over layer
and placing glass mat under the wedges.
All the respective wedges are driven by matching with respective ventilation holes of the
pores.
Similarly all the wedges are driven in all respective slots by blocking the top bars.
After completion top bars laying top bars are subjected to D.C. high voltage.
All connecting rings assemble as per the drawing requirements, and then the phase
groups are processed by jointing, bracing and insulation. After completion of jointing bracing
and insulation once again it is subjected to D.C. high voltage. Termination of desired RTD’S
on one side for monitoring the post curing temperature.
INSULATION SYSTEMS
CHAPTER 5
The experience with Bitumen system has been generally satisfactory & practically
negligible service failure has been reported on these sets.
Mechanical damage most commonly associated with this system ie., tape separation, due
to thermal expansion of the winding during normal or abnormal temperature eyeing is not
met any of sets.
Though outage due to insulation failures has been considerably low, yet these machinery
would need to be attended to have life extension above their estimated life of 25 years.
Major inspection of the machine condition is by checking the healthiness of windings &
life of bar insulation.
Rehabilitation, if needed, requires restoration of varnish, removal of bitumen & cleaning,
tightening of fasteners/supports, modification of busbars, use of new wedges & other
winding components.
Large & medium range motors are provided with following insulation system.
1.Resin flux Insulation System : This system is used on earlier designs & where duplicate or
spare motors to suit the customer requirements are required. In the coming years this system may
become absolute.
2.Resin Rich micalastic Insulation System : The system provides use of Resin rich polyester
backed epoxy micafolium on straight portion & resin rich polyester backed epoxy mica paper
tape on overhang with a final layer of polyester shrink tape. The system is highly productive
during coil manufacture and housing.
3.Resin poor Micalastic Insulation System: Resin poor micalastic system is adopted for large
range Ac Induction and synchronous machines. Theses are designated to meet specific customer
requirement hence for unique in nature to each other. The main insulation consists of resin poor
epoxy mica paper tape all over the oil periphery with varying number of layers on straight and
overhang portions.
1.Epoxy resin content is about 8%. 1.Epoxy resin content is about 40%.
2.This method follows Thermo Setting 2. This method also follows Thermo Setting
Process. Process.
3.There is a need for addition of resin from 3. Further addition of resin is not required from
outside. outside.
4.Time required for this cycle is less.
4.Its a very long process and time consuming.
5.Repairing is very difficult.
5.Repairing is easy.
CHAPTER 6
6.1 INTRODUCTION TO VPI SYSTEM:
DR. MEYER brought the VPI system with the collaboration of WESTING HOUSE in the year
1956. Vacuum Pressure Impregnation has been used for many years as a basic process for
thorough filling of all interstices in insulated components, especially high voltage stator coils and
bars.
VPI is a process, which is a step above the conventional vacuum system. VPI includes
pressure in addition to vacuum, thus assuring good penetration of the varnish in the coil.
The result is improved mechanical strength and electrical properties. With the improved
penetration, a void free coil is achieved as well as giving greater mechanical strength.
With the superior varnish distribution, the temperature gradient is also reduced .
In order to minimise the overall cost of the machine & to reduce the time cycle of the
insulation system vacuum pressure Impregnated System is used.
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 VPI process, in which first the
stator is vacuum dried and then impregnated in resin bath under pressure of Nitrogen
gas.
6.4 PROCESS:
1.General:
• The jobs that are entering tank for Vacuum Pressurised Impregnation shall not have any
oil based coatings. Any such, rust preventive/ corrosion preventive viz., red oxide etc.,
shall be eliminated into the tank.
• Resin in the storage tank shall be stored at 10 to 12C and measured for its
viscosity, viscosity rise.
• Proper functioning of the impregnation plant and curing oven are to be checked
by production and cleared for taking up of job for impregnation
2.Preheating:
• The job is to be loaded in the curing oven and heated. The temperature is to be
monitored by the RTD elements placed on the job and the readings are logged by
production. The time of entry into the oven, time of taking out and the temperature
maintained are to be noted. Depending on convenience of production the jobs can be
preheated in impregnation tank by placing them in tubs.
• The impregnation tubs used for impregnation of jobs are to be heated in the
impregnated tank itself, when the jobs are preheated in the curing oven.
3. Impregnation:
By the time, the preheating of job is completed, it is to be planned in such a way that the
heating of tub and tank heating matches with the job. This is applicable when the job is heated in
the curing oven separately. The preheated job is to be transferred into the tub by crane handling
the job safely and carefully with out damage to the green hot insulation.
The warm tub with job is inserted into impregnation tank by sliding on railing, in case of
horizontal tank. The thermometer elements are to be placed at different places on the job. The
connection for inlet resin is to be made for collection of resin into tub. After ensuring all these
the lid of the impregnation tank is closed. In case of vertical tank the job along with tub is
slinged and inserted carefully into impregnation tank without damage to insulation.
The job is to be dried under vacuum. Drain out the condensed moisture/ water at the
exhausts of vacuum pumps for efficient and fast vacuum creation. Also check for oil replacement
at pumps in case of delay in achieving desired vacuum.
The resin is allowed into the impregnation tank tub if required from various storage
tanks one after the other up to a level of 100mm above the job generally, after which the resin
admission is stopped. After 10mins of resin settling the tank is to be pressurized by nitrogen.
While admitting resin from storage tanks pressurize to minimum so that nitrogen will not affect
resin to spill over in tank.
• Pressurizing/gelling
The resin that is pressurized as per pressure cycle by which the opening of relevant valves
will allow the resin to come back to the storage tank. The job also shall be allowed for dripping
of residue of resin for about 10min. After dripping, withdrawal of resin in various storage tanks
is to be carried out.
The lid is then opened after taking precautions of wearing mask and gloves for the
operating personnel as a protection from fumes. The job is withdrawn from
impregnation tank by sliding on railing for horizontal and slinging on to crane for
vertical impregnation tanks.
4. Post curing: The job is post heated. The time for raising from job temperature to this
temperature as per relevant annexure. The time at which the heating is started, achieved and
maintained is to be logged.
5.Electrical testing:
All jobs that are impregnated till above process, are to be tested for electrical tests. After
ensuring that all the temperature/vacuum conditions stipulated for drying, impregnation and
curing operations have been properly followed, the job is to be released for this operation.
ROTOR
CHAPTER 7
7. ROTOR:
Rotor is the rotating part of alternator. It is used to support field winding placed in slots on the
rotor.
Solid rotors are manufactured from forged alloy steel with suitable alloying elements to achieve
very high mechanical and superior magnetic properties. This type of rotor can withstand even
upto speed of 3000 rpm. Rectangular or trapezoidal rotor slots are accurately machined to close
tolerances on slot milling machine.For indirectly cooled generator rotors, ventilation slots are
machined in the teeth.
For directly cooled rotors, sub slots are provided for cooling Generator rotors of 1500 RPM are
of round laminated construction. In this case rotor is made up of two parts (1) core, (2)
lamination. The outer diameter of core and the inner diameter of laminations are equal. So for
inserting the core inside the laminations the laminations are first red heated at medium
temperature for 15 hours in BELL FURNACE. After that the core is shrunk fitted inside the
laminations. Thus punched and varnished laminations of high tensile steel are mounted over
machined shaft and are firmly clamped by end clamping plates.
7.1ROTOR SHAFT :
Rotor shaft is a single piece solid forming manufactured from a vacuum casting. It is forged from
a vacuum cast steel ingot. Slots for insertion or the field winding are milled into rotor body. The
longitudinal slots are distributed over the circumference such that two solid poles are obtained.
To ensure that only a high quality product is obtained, strength tests, material analysis and
ultrasonic tests are performed during the manufacture of rotor. The high mechanical stresses
resulting from the centrifugal forces and short circuit torque’s call for a high quality heat treated
steel. After completion, the rotor is balanced in various planes at different speeds and then
subjected to an over speed test at 120% of the rated speed for two minutes.
Approximately 60% of rotor body circumference has longitudinal slots which hold the field
winding. Slot pitch is selected so that the two solid poles are displaced by 180 degrees. The rotor
wedges act as damper winding within the range of winding slots. The rotor teeth at the ends of
rotor body are provided with axial and radial holes enabling the cooling air to be discharged into
the air gap after intensive cooling of end windings.
7.2 ROTOR WINDINGS :The rotor windings consist of several coils inserted into the slots
and series connected such that two coil groups form one pole. Each coil consists of several series
connected turns, each of which consists of two half turns connected by brazing in the end
section. Thickness of each strip can be made upto 10.5 mm but here in BHEL we make only upto
5.3 mm. The rotor bearing is made of silver bearing copper ensuring an increased thermal
stability. For ventilation purpose the slots are provided on the coil and on inter strip insulation
layer both.
The individual turns of coils are insulated against each other by interlayer insulation. L-shaped
strips of laminated epoxy glass fiber fabric with nomex filter are used for slot insulation.
Fig: rotor winding.
The slot wedges are made of high electrical conductivity material and thus act as damper
windings. At their ends the slot wedges are short circuited through the rotor body. The inter
space between the overhang is called slot through.
7.2.1CONSTRUCTION
The field winding consists of several series connected coils inserted into the longitudinal slots of
rotor body. The coils are wound so that two poles are obtained. The solid conductors have a
rectangular cross section and are provided with axial slots for radial discharge or cooling air. All
conductors have identical copper and cooling duct cross section. The individual bars are bent to
obtain half turns. After insertion into the rotor slots, these turns are brazed to obtain full turns.
The series connected turns of one slot constitute one coil. The individual coils of rotor are
connected in a way that north and south poles are obtained.
7.2.2 CONDUCTOR MATERIAL: The conductors are made of copper with a silver
content of approximately 0.1%. As compared to electrolytic copper, silver alloyed copper
features high strength properties at high temperatures so that coil deformations due to thermal
stresses are eliminated.
7.2.3INSULATION
The insulation between the individual turns is made of layer of glass fiber laminate.
The coils are insulated from the rotor body with L-shaped strips of glass fiber laminate with
nomex interlines.
To obtain the required leakage paths between the coil and the rotor body thick top strips of glass
fiber laminate are inserted below top wedges. The top strips are provided with axial slots of the
same cross section and spacing as used on the rotor winding. Insulation b/w overhang is done by
blocks made of HGL.
The spaces between the individual coils in the end winding are filled with insulated members
that prevent coil movement. Two insulation plates held by HGL high glass laminate plates
separate the different cooling zones in the overhangs on either sides.
The centrifugal forces of the rotor end winding are contained by single piece rotor retaining
rings. Retaining rings are made of non-magnetic high strength steel in order to reduce stray
losses. Each retaining ring with its shrink fitted. Insert ring is shrunk on to the rotor body in 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 windings. One end of each
ring is shrunk fitted on the rotor body while the other end overhangs the end windings without
contact on the rotor shaft. This ensures an unobstructed shaft deflection at the end winding.
BEARINGS
VENTILATION AND COOLING
EXCITER SYATEM
CHAPTERS 8 & 9
8.BEARINGS
The turbo generators are provided with pressure lubricated self-aligning elliptical type bearings
to ensure higher mechanical stability and reduced vibration in operation. The bearings are
provided with suitable temperature element devices to monitor bearing metal temperature in
operation. From inside the bearings are made of very soft metal called Babbitt so that rotor
doesn’t get harmed even if it comes in contact with Babbitt. Inside this Babbitt there is a very
thin film of pressurized lubrication oil on which the shaft rotates.
The temperature of each bearing is monitored with two RTDs (Resistance Thermo Detectors)
embedded in the lower bearing sleeve such that the measuring point is located directly below the
babitt. To prevent damage to the journals due to shaft currents, bearings and oil piping on either
side of the non-drive end bearings are insulated from the foundation frame. For facilitating and
monitoring the healthiness of bearing insulation, split insulation is provided.
Closed circuit air cooling with water or air coolers mounted in the pit.
Closed circuit hydrogen cooling with water or hydrogen coolers mounted axially on the
stator frame.
The fan design usually consists of two axial fans on either made of cast aluminum with
integral fan blades or forged and machined aluminum alloy blades screwed to the rotor.
In case of 1500 RPM generators, fabricated radial fans are provided
EXICTATION SYSTEM:
The basic use of given exciter system is to produce necessary DC for turbo generator system.
Principal behind this is that PMG is mounted on the common shaft which generates electricity
and that is fed to yoke of main exciter. This exciter generates electricity and this is of AC in
nature. This AC is that converted into DC and is that fed to turbo generator via C/C bolt. For
rectifying purpose we have RC block 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
than it sends the current to rotor as per requirement.
Fig: BLE exciter
TESTING
CHAPTER 10
To ensure that all functional requirements are fulfilled, and to estimate the performance of
generator, the TURBO GENERATORS are required to undergo some tests. For testing, the
TURBO GENERATOR was mechanically coupled to a drive motor-motor generator set with
gearbox. The rotor was excited by thyristor converter system located in an independent test room
and the operation was controlled from the test gallery. The following first two tests will be
conducted on the stator and rotor before assembling and the third and final routine tests will be
conducted after assembling the turbo generator.
10.1 ROUTINE TETSTS ON TURBO GENERATOR
The machine is rolled and run at rated speed after ensuring the bearing oil and kept at rated
speed for stabilization of bearing temperatures.
The vibrations are measured at rated speed on both the bearing housings in Horizontal,
Vertical and Axial directions.
The temperature of stator is monitored by monitoring RTDs embedded in core, tooth and
winding. The vibrations should be less than 5 microns and noise level should be in between 75-
90 db.
The machine is prepared for short circuit characteristic using current transformers and
shorting the terminals . The machine is run at rated speed and drive motor input voltage and
current are noted and machine is excited gradually in steps, at 20%, 40%,60%,80%,100% rated
current of machine (In).
The excitation is reduced and cut off. The speed is reduced and the machine is cooled at
lower speed. The temperature are checked from machine RTD’s. The machine is stopped when it
is sufficiently cooled down. The stator winding temperature should be less than 60 C) From
the Short Circuit test, we will get copper losses.
The short circuit characteristics is plotted from SCC results by selecting X-axis as field
current and Y-axis as % rated current.
The machine is run at rated speed and the motor input voltage and current are noted and
machine is excited gradually in steps, cat 20%,40%,60%,80%,90%,95%,100%,105%,110% and
120% of rated voltage of machine (En).
The excitation is reduced, cut off, the speed is reduced, and the machine is cooled at lower
speed. The temperatures are checked from machine RTD’s. The machine is stopped when it is
sufficiently cooled down. The stator core temperatures to be less than 60 C.
The Open Circuit Characteristics is plotted on a graph paper from OCC results by selecting
X-axis as field current and Y-axis as % rated voltage.
When the rotor shaft rotates inside the stator there will be some induced EMF will be
developed inside the rotor. In addition, this voltage will go to the bearings and pedestal and to
the earth as it is grounded and it will again come back to the pedestal, to the bearings through the
earth. It will become a cyclic process. This voltage has to be reduced otherwise, the rotor will get
heated. For this bearing pedestal is placed on, insulation called HGL.
When the machine is under OCC condition at 100% rated voltage, phase sequence of
generator is checked using a phase sequence indicator across PT.
A variable 50 HZ A.C voltage of single phase is applied across the input leads and readings
of voltage and current are noted down from 50v-200 v in steps of 50V.
Insulation Resistance of the stator and rotor windings is measured separately before and after
high voltage test using Megger of 2500 V for stator & 1000 V for rotor windings. The Insulation
Resistance values are taken at 15 sec and at 60 sec. The ratio of insulation resistance at 15 sec
and 60 sec is known as Absorption Coefficient. Absorption Coefficient = IR at 60”/IR at
15” .This Absorption Coefficient for High Voltage test should be > =1.3
The High Voltage is applied to windings by increasing gradually to required value and
maintained for one minute and reduced gradually to minimum. The transformer is switched off
and winding is discharged to earth by shorting the terminal to earth using earthing rod connected
to earthen wire. The test is conducted on all the phases and rotor winding separately. When High
Voltage test is done on one phase winding, all other phase windings, rotor winding,
instrumentation cables and stator body is earthed.
Up = Excitation voltage
In cold condition means that measuring the D.C. resistance of the stator and rotor windings
before testing. Variation of D.C is 5% acceptable. D.C. Resistance’s of stator and rotor windings
are measured separately using micro ohmmeter. The instrument terminals are connected to the
machine terminals and proper range in the meter is selected.
EVALUATION OF SHORT CIRCUIT RATIO:
From the test data Short Circuit Ratio is calculated using the formula.
S.C.R= Field current at 100% Rated voltage from OCC/Field current at 100% rated current from
SCC.
CONCLUSION
AND
FUTURE SCOPE
CHAPTER 11
CONCLUSION :
REFERENCES:
www.indiamart.com
www.eriks.co.uk
www.seimens.com
www.bhel.com