INTRODUCTION BHEL was established more than 50 years ago when its first plant was setup in Bh opal

ushering in the indigenous Heavy Electrical Equipment Industry in India. A dream which has been more than realized with a well recognized track record of p erformance it has been earning profits continuously since 1971-72 and achieved a turnover of Rs 2,658 crore for the year 2007-08, showing a growth of 17 per cen t over the previous year. Bharat Heavy Electricals Limited is countrys Navratna com pany and has earned its place among very prestigious national and international companies. It finds place among the top class companies of the world for manufac ture of electrical equipments. BHEL caters to core sectors of the Indian Economy viz., Power Generation s & Tra nsmission, Industry, Transportation, Telecommunication, Renewable Energy, Defens e, etc. BHEL has already attained ISO 9000 certification for quality management, and ISO 14001 certification for environment management and OHSAS 18001 certific ation for Occupational Health and Safety Management Systems. The Company today e njoys national and international presence featuring in the Fortune International -500 and is ranked among the top 10 companies in the world, manufacturing power g eneration equipment. BHEL is the only PSU among the 12 Indian companies to figur e in Forbes Asia Fabulous 50 list. Probably the most significant aspect n .The constant reorientation of the me with a philosophy that has led to m concepts to commissioning not only and transportation. of BHELs growth has been its diversificatio organization to meet the varied needs in ti total development of a total capability fro in the field of energy but also in industry

In the world power scene BHEL ranks among the top ten manufacturers of power pla nt equipments not only in spectrum of products and services offered, it is right on top. BHELs technological excellence and turnkey capabilities have won it worl dwide recognition. Over 40 countries in world over have placed orders with BHEL covering individual equipment to complete power stations on turnkey basis

BHEL A Brief Profile BHEL is the largest engineering and manufacturing enterprise in India in the ene rgy related infrastructure sector today. The wide network of BHEL s 14 manufactu ring division, four power Sector regional centers, over 150 project sites, eight service centers and 18 regional offices, enables the Company to promptly serve its customers and provide them with suitable products, systems and services effi ciently and at competitive prices. While the company contributes more then 75% o f the national grid, interestingly a share of 45% comes from its single unit. An d this is none other then BHEL-Hardwar. BHEL has:Installed equipment for over 90,000MW of power generation--- for utilities capti ve and industrial users.

Supplied over 2, 25,000 MVA transformer capacity and other equipment operating i n transmission and distribution network up to 400 kV (AC & DC). Supplied over 25,000 motors with drive control systems to power projects, petroc hemicals, refineries, steel, aluminum, fertilizers, cement plants etc. Supplied Traction electrics and AC/DC locos to power over 12,000 kms railway net work. Supplied over one million valves to power plants and other industries.

BHEL An Overview BHEL today is the largest Engineering Enterprise of its kind in India with excel lent track record of performance, making profits continuously since 1971-72. BHEL s vision is to become a world-class engineering enterprise, committed to en hancing stakeholder value. The company is striving to give shape to its aspirati ons and fulfill the expectations of the country to become a global player. BHEL business operations cater to core sectors of Indian Economy like. Power Industry Transportation Transmission Defenses etc. The greatest strength of BHEL is its highly skilled and committed 42,600 employe es. Every employee is given an equal opportunity to develop himself and grow in his career. Continuous training and retraining, career planning, a positive work culture and participative style of management all these have engendered develop ment of a committed and motivated workforce setting new benchmarks in terms of p roductivity, quality and responsiveness. POWER SECTOR Power generation sector comprises thermal, gas, hydro and nuclear power plant bu siness .BHEL supplied utility sets accounts to 87,646 MW 65% of the total insta lled capacity of 1,38,175 MW in the country , as against nil in 1969 -70. As part of Indias largest Solar Power-based Island Electrification Project in Ind ia, Bharat Heavy Electricals Limited (BHEL) has successfully commissioned two Gr id-Interactive Solar Power Plants of 100 KW each in Lakshadweep. With this, the company has commissioned a total of eleven Solar Power Plants in the Lakshadweep islands, adding over 1 MW of Solar Power to the power generating capacity of the coral islands in the Arabian Sea. BHEL has proven turnkey capabilities for executing power projects from concept t o commissioning and manufactures boilers, thermal turbine generator sets and aux iliaries up to 500MW. It possesses the technology and capability to procure thermal power generation u

p to 1000MW. Co- generation and combined cycle plants have also been introduced. For the efficient use of high ash content coal BHEL supplies circulating fluidiz ed boiler. BHEL manufacturers 235MW nuclear sets and has also commenced production of 500MW nuclear turbine generator sets. Custom made hydro sets of Francis, pelton and kepian types for different head di scharge combination are also engineering and manufactured by BHEL. In, all 700 utility sets of thermal, hydro, gas and nuclear have been placed on the company as on date. The power plant equipment manufactured by BHEL is based on contemporary technology comparable to the best in the world and is also inter nationally competitive. The Company has proven expertise in Plant Performance Improvement through renova tion modernization and up rating of variety of power plant equipment besides spe cialized know how of residual life assessment, health diagnostics and life exten sion of plants. POWER TRANSMISSION AND DISTRIBUTION (T&D) --BHEL offer wide-ranging products and systems for T & D applications Products. manufactured include power transformers, instrument transformers, dry type trans formers, series and shunt reactor, capacitor tanks, vacuum and SF circuit breake rs gas insulated switch gears and insulators. A strong engineering base enables the Company to undertake turnkey delivery of e lectric substances up to 400 kV level series compensation systems (for increasin g power transfer capacity of transmission lines and improving system stability a nd voltage regulation), shunt compensation systems (for power factor and voltage improvement) and HVDC systems (for economic transfer of bulk power). BHEL has i ndigenously developed the state-of-the-art controlled shunt reactor (for reactiv e power management on long transmission lines). Presently a 400 kV Facts (Flexib le AC Transmission System) project under execution. INDUSTRY SECTOR BHEL is a major contributor of equipment and system to important industr ies like Cement Petrochemicals Fertilizers Steel papers Refineries Mining and telecommunication BHEL has indigenously developed the state-of-the-art controlled shunt reactor (f or reactive power management on long transmission lines). Presently a 400 kV FAC TS (Flexible AC Transmission System) projects is under execution. The range of system and equipment supplied includes:Captive power plants High speed industrial drive turbines Industrial boilers and auxiliaries Waste heat recovery boilers

Gas turbine pump, valves, seamless steel tubes Heat exchangers Process control etc. The Company is a major producer of large-size thruster devices. It also supplies digital distributed control systems for process industries, and control & instr umentation systems for power plant and industrial applications. BHEL is the only company in India with the capability to make simulators for power plants, defen se and other applications. The Company has commenced manufacture of large desalination plants to help augme nt the supply of drinking water to people. TRANSPORTATION BHEL is involved in the development design, engineering, marketing, production, installation, and maintenance and after-sales service of Rolling Stock and tract ion propulsion systems. In the area of rolling stock, BHEL manufactures electric locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duly applications. BHEL is also producing rolling stock for special applications viz., overhead equipment cars, Special well wago ns, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house use, BHEL manufactures traction propulsion systems for other rolling stock prod ucers of electric locomotives, diesel-electric locomotives, electrical multiple units and metro cars. The electric and diesel traction equipment on India Railwa ys are largely powered by electrical propulsion systems produced by BHEL. The co mpany also undertakes retooling and overhauling of rolling stock in the area of urban transportation systems. BHEL is geared up to turnkey execution of electric trolley bus systems, light rail systems etc. BHEL is also diversifying in the a rea of port handing equipment and pipelines transportation systems. TELECOMMUNICATION--BHEL also caters to telecommunication sector by way of small, medium and large s witching system.

HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)

At Hardwar, against the picturesque background of Shivalik Hills, 2 important ma nufacturing units of BHEL are located viz. Heavy Electrical Equipment Plant ( HEEP) & Central Foundry Forge Plant (CFFP). The hum of the construction machiner y working started under Shivalik Hills during early 60s and sowed the seeds of o ne of the greatest symbol of Indo Soviet Collaboration Heavy Electrical Equipmen t Plant:Consequent upon the technical collaboration between India and USSR in 1959, BHELs prestigious unit, Heavy Electrical Equipment plant (HEEP), was established in O

ctober, 1963, at Hardwar. It started manufacturing thermal sets in 1967 and now thermal sets of 210, 250 and 500 MW, including steam turbines, turbo-generators, condensers and all associated equipments, are being manufactured. This unit is capable of manufacturing thermal sets up to 1000 MW. HEEP-manufactured gas turbi nes, hydro turbines and generators, etc., are not only successfully generating e lectrical energy within and outside the country, but have also achieved a histor ic record of the best operational availability and plant load factor. The Company is embarking upon an ambitions growth path through clear vision, mis sion and committed values to sustain and augment its image as a world class ente rprise. VISION World-class, innovative, competitive and profitable engineering enterprise provi ding total business solutions. MISSION The leading Indian engineering enterprise providing quality products systems and services in the fields of energy, transportation, infrastructure and other pote ntial areas. VALUES Meeting commitments made to external and internal customers. Foster learning creativity and speed of response. Respect for dignity and potential of individuals. Loyalty and pride in the company. Team playing Zeal to excel. Integrity and fairness in all matters. ESTABLISHMENT AND DEVELOPMENT STAGES: Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in the ar ea of Scientific, Technical and Industrial Cooperation. DRR prepared in 1963-64, construction started from October 63 Initial production of Electric started from January, 1967. Major construction / erection / commissioning completed by 1971-72 as per origin al DPR scope. Stamping Unit added later during 1968 to 1972. Annual Manufacturing capacity for Thermal sets was expanded from 1500 MW to 3500 MW under LSTG. Project during 1979-85 (Sets up to 500 MW, extensible to 1000/13 00 MW unit sizes with marginal addition in facilities with the collaboration of M/s KWU-Siemens, Germany. Motor manufacturing technology updated with Siemens collaboration during 1984-87 . Facilities being modernized continually through Replacements / Reconditioning-Re trofitting, Technological / operational balancing. CLIMATIC AND GEOGRAPHICAL CONDITIONS: Hardwar is in extreme weather zone of the Western Uttar Pradesh of India and tem perature varies from 2oC in Winter (December to January) to 45oC in Summer (Apri l-June); Relative humidity 20% during dry season to 95-96% during rainy season. Longitude 78o3 East, Latitude 29 o55 5" North. Height above Mean Sea Level = 275 meters. Situated within 60 to 100 KMs of Foot-hills of the Central Himalayan Ranges; Gan ges flows down within 7 KMs from the Factory area. HEEP is located around 7 KMs on the Western side of Hardwar city. POWER & WATER SUPPLY SYSTEM:

40 MVA sanctioned Electric Power connection from UP Grid (132 KV / 11KV / 6.6 KV ) (Connected load around 185 MVA) 26 deep submersible Tube Wells with O.H. Tanks for water supply. A 12 MW captive thermal power station is located in the factory premises. Facilities (Plant Premises) S.No. Area/ Block Major Facilities Products 1. Block I (Electrical Machines) Machine Shop., Windings bar preparation assembling, pain ting section, packing& preservation, over speed balancing, test bed test stand, babbiting, micalastic impregnation etc. Turbo Generator, Generator excit ers, motors (AC& DC) 2. Block II (Fabrication Block) Markings, welding ,Cutting, straightening, gas cutting press, , grinding , assembly, heat treatment, cleaning & Shot blasting, machining, fabrication of pipe coolers, painting Large size fabricated assemblies/ components for power e quipments 3. Block III (Turbines & Auxiliary Block) Machining, facing wax melting, broaching, assemb ly preservation & packing, test stands/ station, painting grinding, milling, pol ishing etc. Stem turbines, hydro turbines, gas turbines, turbine bladders, s pecial tooling. 4. Block IV (Feeder Block) Bar winding, mechanical assembly, armature winding, sheet metal working marching, copper profile drawing electroplating, impregnation, machining & preparation of insulating components plastic molding, press molding Windings for turbo generators, hydro generators insulation for AC & DC motors, insulatin g components for TG, HG & Motors control panel, contact relays master control et c. 5. Block V Fabrication, pneumatic hammer for forgings, gas fired furnaces, hydraulic manipulators Fabricated parts of steam turbine, water box, storage ta nk hydro turbine parts, hydro turbines assemblers & Components 6. Block VI (Fabrication) Welding, drilling, shot blasting, CNC flame cutting ,CNC deep dr illing, Shot basting, sheet metal work, assembly Fabricated parts of stea m turbine water box, stronger tanks, hydro turbine parts, Hydro turbines assembl ies & components, 7. Block- VI (Stamping & Die Manufacturing) Machining, turning, grinding, jig boring stamping presses, de va rnishing, degreasing & de rusting, varnishing sport welding, painting. Wooden packing, spacers etc. 8. Block- VII (wood working) Wood Cutting, machines, grinding , packi ng Wooden packing, spacers etc. 9. Block VIII Drilling ,turning, saw, cutting, welding, tig welding LP Heater ejectors glad, steam cooler oil coolers, ACG collers, oil tanks, beari ng covers. 10. Services plat TPS : Power generation equipment & auxiliaries plat capa city 12 MW Power generation PGP Plat : Boiler Type gas generators Producer gas Acetylene Plat : A fully automated plant for acetylene generatio n & filling in cylinder Acetylene gas Compressor House: 4 No. Compressors of rating 100 m2 / min Compressed air Oxygen Plat : 3 air separation unit 4 air compressors Oxygen g

as Nitrogen gas 132 KV substation : 2 Nose 16.7 MVA/ 11 KV, one no. 20 MVA & one no. 12.5 MVA 132/6.6 KV transformer & other allied equipment Power supply 11. Motor transport A fleet of vehicles comprising of cars, jeeps trekkers, buses, mini buses motorcycles , fire tenders trucks etc. Transport servic e 12. Telecommunication A 2000 line main exchange for internal communica tion 3 no Satellite exchange Telephone service 13. Hydro Turbine Lab 3 test beds with electronic instrumentation. It consists of cavitations test bed for reactions turbine & hydrodynamic test bed f or Impulse turbines facilities for carrying out filed test at hydro power sets. Testing of turbine models 14. HRDC Class room with audiovisual facilities workshop with facilities for turnings fitting machining, weeding, electrical work carpentry work Training to Employees, VTs Apprentices, Contractors & Customers 15. Engineering CAD Work stations, personal computer reprographic facili ties like ammonia printing, semi dry printing machine, Xerox process, micro film ing facilities Design and drawings of all products 16. Computer Center ICIMs series 39 DX level 270-320 computer system HCL magn um mini compute system , ESPL SM 32 mini computer Nexus 3500 CAE work station, P Cs etc. IT services 17. CPL (Central plant Lab.) Testing Lab for new materials & sample c omponents Testing of components

Repair / Reconditioning Of Electrical

Machines

Rotating electrical machines of various types and ratings are required for the o peration of any industrial. plant or power plant. Failure or breakdown of a rota ting electrical machine can occur for various reasons at any time during the lif e of the machine. For any plant, the cost of downtime as a result of failure or breakdown of an electrical machine would be enormous. The costs of replacement o f these machines often used for very critical operations, are quite exorbitant a nd the process of procurement very cumbersome. So, most of the times, the indust ry/power plant goes in for repair/reconditioning of their old machines. At this critical juncture, BHEL, Electrical Machines Repair Plant (EMRP) steps i n to cater to this need of the industry. The technological expertise of BHEL as the premier manufacturer of electrical machines in India is available to the ind ustry through EMRP. In India, when any industrial plant or power plant is set up, the rotating elect rical machines required for the operation of the plant are procured from various companies from all over the world. EMRP has developed the capability to repair rotating electrical machines of both BHEL and non-BHEL make having technology of the sixties or technology of the nineties. In short, EMRP uses Tomorrow s techno logy in Yesterday s equipment. In most cases of imported, non-BHEL or very old ma chines, technical details / drawings are often not available. Moreover, the tec hnology and the insulating material used in very old machines have by now become obsolete. BHELs EMRP has developed the technical expertise in usingReverse Engin eering techniques for designing and manufacturing windings and components of the se old and not-so-old non-BHEL machines. ACTIVITY PROFILE A. Assessment of Fault - When a machine is received at EMRP, a series of tests a

nd measurements,as follows, are carried out to assess the nature of fault and th e extent of damage to the machine: Visual inspection of machine: Electric motors are normally received in assembled form. Sometimes only the damaged stator or rotor or armature is received. So, a s a first step in the process of repair a record of the condition of the stator, rotor and assembly components of the machine is made. Electrical Test on stator/rotor like IR & PI measurement, winding resistance, im pedance measurement and core flux test. Drop test and if required bar to bar tes t onDCarmature/commutator Mechanical tests on rotor like run-out check of the shaft, dye penetration test and ultrasound test B. Determination the method of Repair/Reconditioning After assessment of fault that has occurred in the machine, it can be designated as either mechanical or electrical. Most of the times, mechanical faults would result in an electrical failure of the machine. Sometimes electrical faults also cause mechanical damage to the machine. The next step after the assessment of the fault and the extent of ensuing damage on the various parts of the machine is to decide about the modus operandi to be followed for refurbishing the machine. The method of repair to be done depends on the type of fault that has occurred on the machine. The repair/reconditioning of electric machines done at EMRP can be broadly categ orised as presented in Table-I. TABLE-I TYPES OF MECHANICAL & ELECTRCIAL REPAIR JOB CARRIED OUT

Type of Fault Type of Repair Mechanical Breaking of shaft Bearing seizure Breaking of rotor bar Hot spots of core Breaking or wearing out of assembly components Reshafting Change of bearing and repair/replacement of bearing housing components Recaging Restaggering of core / Electro-chemical cleaning Repair / replacement of the damaged component Electrical Insulation flash-over Inter-turn fault Cable flash-over Commutator Inter-turn short in field coils Change / repair of winding Change of winding Cable replacement Commutator rebuilding using old parts Replacement/Re-insulation of the field coils depending upon the fault C.Designing of Winding/Shaft/Assembly Components using REVERSE ENGINEERING TECHN IQUES for non-BHEL Machines Reverse Engineering Technique is the process of generating detailed manufactu ring drawings/details of a sub-assembly from the final equipment/ component. The standard engineering practices of designing an equipment is by first designi

ng all the sub-assemblies of the component and then integrating all the sub-asse mblies to form the final equipment/component. The dimensions and the mechanical and electrical properties of every component that forms the part of the sub-asse mbly of the equipment determine the dimensions and properties of the subsequent major assembly. Reverse engineering is required when we have to work backwards from the complete machine. Any damaged component or winding has to be designed to suit the origin al machine frame. The liberties available to a designer of new machines are not available while trying to retrofit an old or damaged machine. Often the techniqu es and material used in the old machines are now obsolete. So the components hav e to be designed within the constraints of the old machine for the present-day techniques and materials. The method of reverse engineering can be elaborated as (aDetaileddimensioning of the machine (b) Cross-checking the dimension by suitable means (c) Detailed dimensioning of the component to be redesigned (in case the item is broken or sheared, as many dimensions as possible) (d) Conducting tests to evaluate the material characteristics of thecomponent (e) Design and preparation of drawings for the new component (f) Checking the fitting of the new component with its matching components (g) Deciding on the technology and system to be used for manufacturing the component The design details/drawings required for the repair of the non-BHEL machine are developed using Reverse Engineering Techniques. D. Quality Control During Various Stages Of Repair/Manufacture of Winding/Dama ged Components EMRP has firmly established quality management system that ensures that quality control checks are done during various stages of repair. After completing the re pairs, the machines are subjected to proof testing and routine testing to prove the soundness of the repaired/reconditioned machine. The quality checks are based on International/National/BHEL standards. BHEL stan dards are generally based on International/National standards. But in crucial ar eas, the internal standards followed by BHEL are more stringent than the corresp onding International/National standards. A computerised databank of the results of quality checks are maintained for records and future references. Some of the checks done as per Quality Assurance Plan during different stages of repair are: During coil manufacture and coil assembly (a) Dimensional and specified checks of incoming raw material such as copper conductor, insulating materials & tooling etc. (b) Dimensional and configuration check of coil stacks. (c) Inter-turn testing of coil stacks. (d)Corona resistance measurements (above 5 kV rated machines). (e) Tan- measurements of coils. (f) High voltage proof test on 100% of all coils for slot I nsulation and overhang insulation. (g) Inter-turn testing on 100 % of finished coils.

(h) (i)

During rewinding, AC HV test on the coils after wedging as they are being assembled. Inter-turn test on all coils after assembly but before making series connections.

After completion of rewinding/repairs/ reconditioning of High voltage 3-phase Induction motors (a) IR / PI measurements by motorized megger. (b) Inter-turn test on stator windings. (c) AC HV test on windings to earth as per relevant standards. (d) Winding resistance of stator (& rotor wherever applicable). (e) Checking of RTD / BTD / Heaters resistance & IR values. (f) No load run of the machine. (g) Vibration measurements on the motor during no load run. (h) Bearing / winding temperature measurements during no load run. (i) Tan delta test on wound stator (Optional). (j) Turns ratio test (for wound rotor only). After completion of repairs/reconditioning of DC machines (a) IR measurements of armature, main pole and inter-pole coils. (b) Winding resistance / impedance tests main pole and inter-pole coils. (c) Milli-volt drop test on armature. (d) Neutral axis checking / setting. (e) AC HV test on armature, main pole and inter-pole coils. (f) No load run of the machine. (g) Vibration measurements on the motor during no load run. (h) Bearing temperature measurements during no load run.

ELECTRICAL MACHINES BLOCK (BLOCK-I) INTRODUCTION--Block-I is designed to manufacturing Turbo Generators, Hydro generators and lar ge and medium size AC and DC Electrical machines. The Block consist of 4 bays: Bay-1 (36*482 meters), Bay-2 (36*360 meters) and Ba y-3 and Bay-4 of size 24 *360 meters each. For handling and transporting the var ious components over-head Crane facilities are available, depending upon the pro ducts manufactured in each Bay. There are also a number of self-propelled electr ically-driven transfer trolleys for the inter-bay movement of components /assemb lies. Conventional bay -wise broad distribution of products is as follows :

BAY1 ROTOR SHAFT MACHINING ROTOR SHAFT SLOTTING ED AND BALANCING TUNNEL LARGE SIZE TURBO GENERATORS BAY2 EXCITER SHAFT MACHINING STATOR BODY MACHINING

ROTOR WINDING

OVER SPE

STATOR WINDING TOTAL IM

PREGNATION TEST BED BAY--3 ROTOR SUPPORT BEARING SHAFT SEAL BODY DC MOTOR WINDING (EARLIER) BAY--4 COOLING FANS MACHINING ARRANGEMENT AND OTHER PARTS

BASIC TRAINING DEPARTMENTS: MACHINE SHOP. T/G ROTOR WINDING. H/G IRON ASSEMBLY. EXCITER. T/G STATOR WINDING. TOTAL IMPREGNATION TECHNIQUE. T/G IRON ASSEMBLY. T/G MAIN ASSEMBLY. L.S.T.G ROTOR WINDING. L.S.T.G STATOR WINDING. L.S.T.G MAIN ASSEMBLY. TEST BED. TURBO GENERATOR

Turbo generator or A.C. generators or alternators operates on the fundamental pr inciples of ELECTROMAGNETIC INDUCTION. In them the standard construction consist s of armature winding mounted on stationary element called stator and field wind ings on rotating element called rotor. The stator consists of a cast-iron frame , which supports the armature core , having slots on its inner periphery for hou sing the armature conductors. The rotor is like a flywheel having alternating no rth and south poles fixed to its outer rim. The magnetic poles are excited with the help of an exciter mounted on the shaft of alternator itself. Because the fi eld magnets are rotating the current is supplied through two slip rings. As magn etic poles are alternately N and S, they induce an e.m.f and hence current in ar mature conductors. The frequency of e.m.f depends upon the no. of N and S poles moving past a conductor in 1 second and whose direction is given by Fleming s rig ht hand rule. SYNOPSIS OF THE FUNCTION OF T.G.: 1. The generator is driven by a prime mover which is steam turbine in this case. 2. The other side of generator is provided by a rotating armature of an exc iter which produces A.C. voltage. This is rectified to D.C. by using a rotating diode wheel. 3. The rear end of above exciter armature is mounted by a permanent magnet generator rotor. 4. As the above system is put into operation, the PMG produces A.C. voltage . 5. The voltage is rectified by thyristor circuit to D.C. 6. This supply is given to exciter field. This field is also controlled by taking feedback from main generator terminal voltage, to control exciter field v ariation by automatic voltage regulator. The rectified DC supply out of exciter is supplied to turbo generator rotor winding either through brushes or central w

hich will be directly connected to turbo generator. This depends on the type of exciter viz. DC commutator machines or brushes exciter. 7. The main A.C. voltage is finally available at the stator of Turbo Genera tor.

LSTG AREA

LARGE SIZE TURBO GENERATOR (LSTG) In these types of generators steam turbine does the function of prime mover which rotates the rotor of LSTG and the field winding is supplied D. C. by an exciter. Main types of T.G. are:1. 2. 3. 4. 5. 6. THRI TARI THDI THDD THDF THFF

1st LETTER = (here-T) = 3-phase turbo generator 2nd LETTER = (here H or A) =Medium present for generator cooling (H= hydrogen, A or L=air) 3rd LETTER=type of rotor cooling employed R= radial, F= direct water cooling D= direct axial gas cooling) 4th LETTER= type of as used for stator winding cooling I= indirect gas cooling D= direct gas cooling F= direct water cooling COMPONENTS OF T.G. :1. 2. 3. 4. STATOR Stator frame Stator core Stator winding End covers.

ROTOR

1. 2. 3.

Rotor shaft Rotor windings Rotor retaining rings BEARINGS COOLING SYSTEM EXCITATION SYSTEM

STATOR The generator stator is a tight construction supporting and enclosing stator win ding, core and hydrogen cooling medium. Hydrogen is contained within the frame a nd circulated by fans mounted at either end of rotor. The generator is driven by a direct coupled steam turbine at the speed of 3000 rpm. The generator is designed for continuous rated output. Temperature detector or o ther devices installed or connected within the machine, permits the winding core and hydrogen temperature, pressure and purity in machine. STATOR FRAME The stator frame is used for housing armature conductors. It is made of cylindrical section with two end shields which are gas tight and pressure resist ant. The stator frame accommodates the electrically active parts of stator i.e. the stator core and the stator winding.

The fabricated inner cage is inserted in the outer frame after the stator has be en constructed and the winding completed. STATOR CORE:The stator core is stacked from the insulated electrical sheet steel lamination and mounted in supporting rings over the insulated dovetail guide bars. In order to minimize eddy current losses core is made of thin laminations. Each laminati on layer is made of individual sections. The ventilation ducts are imposed so as to distribute the gas accurately over the core and in particularly to give adeq uate support to the teeth. The main features of core are 1. 2. To provide mechanical support. To carry efficiently electric, magnetic flux.

3.

To ensure the perfect link between the core and rotor.

STATOR WINDING:Each conductor must be capable of carrying rated current without over heating. The stator winding consists of two layers made up of individual bars. Windings f or the stators are made of copper strips wound with insulated tape which is impr egnated with varnish, dried under vacuum and hot pressed to form a solid insulat ion bar. These bars are then placed in the stator slots and held in with wedges to form the end turns. These end turns are rigidly placed and packed with blocks of insulation material to withstand heavy pressure. The stator bar consists of hollow (in case of 500 MW generators) solid s trands distributed over the entire bar cross-section, so that good heat dissipat ion is ensured. In the straight slot portion the strands are transposed by 540 d egrees. The transposition provides for mutual neutralization of the voltage indu ced in the individual strands due to slot cross field and end winding flux leaka ge and ensure that minimum circulating current exists. The current flowing throu gh the conductors is thus uniformly distributed over the entire cross section so that the current dependent losses will be reduced. The alternate arrangement of one hollow strand and two solid strands ens ures optimum heat removal capacity and minimum losses. The electrical connection between top and bottom bars is made by connecting sleeve. Class F insulation is used. The no. of layer of insulation depends on machine voltage. The bars are brought under vacuum and impregnated with epoxy resin, which has very good penetration p roperty due to low viscosity. After impregnation bars are subjected to pressure with nitrogen being used as pressurizing medium (VPI process). The impregnated b ars are formed to the required shape on moulds and cured in an oven at high temp erature to minimize the corona discharge between the insulation and slot wall a final coat of semiconducting varnish is applied to the surface of all bars withi n the slot range. In addition all bars are provided with an end corona protectio n to control the electric field at the transition from the slot to end winding. The bars consist of a large no. of separately insulated strands which are transp osed to reduce the skin effect.

INSULATION OF BARS:A. Vacuum pressed impregnated micaclastic high voltage insulation:-

The voltage insulation is provided according to the proven resin poor mice base of thermo setting epoxy system. Several half overlapped continuous layer of resi n 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 for ces windings hold and insulated rings are used to support the overhang. B. Corona Protection:-

To prevent the potential difference and possible corona discharge between the sl ot wall and the insulation, the section of bars are provided with outer corona p rotection. The protection consists of polyester fluce tape impregnated in epoxy resin with carbon and graphite as fillers. At the transition from the slot to th e end winding portion of the stator bars a semiconductor tape is impregnated. C. Resistance Temperature Detector:-

The stator slots are provided with platinum resistant 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 arma ture core longer, the machine is to be provided with at least 6 resistance therm ometers. The thermometer should be fixed in the slot but outside the coil insula tion. 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 resistance thermome ter depends upon the length of armature. The leads from the detector are brought out and connected to the terminal board for connection onto temperature meter o r relays. Operation of RTD is based on the prime factor that the electric resista nce of metallic conductor varies linearly with temperature END COVERS:The end covers are made up of fabricated steel or aluminum castings. They are em ployed with guide vans on inner side for ensuring uniform distribution of air or gas.

MANUFACTURING OF VARIOUS PARTS OF STATOR:Stator Core Assembly Section:This section is present in BAY-1. Two no. core pits with core building and pres sing facilities are available in this section. The section is also equipped with optical centering device, core heating installation and core loss testing facil ities. Iron Assembly Section:In BAY-2 this section has facilities for stator core assembly of Turbo-generator s and Heavy Electric Motors.

Stator Winding Section:This section is present in BAY-1. The section is located in a dust-proof enclosu re with one no. winding. Platform with two no. rotating installation for assembl y of winding. Resistance brazing machines and high voltage transformers are also available in this section. Bar Preparation Section:This section is present in BAY-1. This section consists of milling machine for l ong preparation, installation for insulation of tension bolts for stator and pre paration of stator winding before assembly. The three phase winding is afraction al pitch two layer type consisting of individual bars. Armature Section:This section is equipped with installations like bandaging machines, tensioning devices, Magnetic putty application machine and 45 KW MF brazing machines for la ying windings in large size DC armatures. Cooling:Heat losses arising in the generator are dissipated through hydrogen. The heat d issipating capacity of hydrogen is eight times to that of air.

ROTOR The moving or rotating part of generator is known as rotor. The axial length of shaft of the rotor is very large as compared to its diameter in case of turbo ge nerators. It is coiled heavily (field coils) as it has to support large amount o f current and voltage. Rotor revolves in most generators at a speed of 3000rpm. Field coils are wound over it to make the magnetic poles and to maintain magneti c strength the winding must carry a very high current. As current flows heat is generated, but the temperature has to be maintained because as temperature raise s problems with insulation becomes more pronounced. With good design and great c are this problem can be solved.

ROTOR SHAFT:The rotor shaft is cold rolled forging 26N1 or MOV116 grade and it is imported f

rom Japan and Italy. Rotor shaft is a single piece. The longitudinal slots are distributed over its c ircumference. After completion, the rotor is balanced in the various planes and different speed and then subjected to an over speed test at 120% of rotor speed. The rotor consists of electrically active portion and two shaft ends approximat ely 60 % of rotor body circumference have longitudinal slots which hold the fiel d 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 sl ots. The rotor teeth at the rotor body are provided in radial and axial poles en abling cooling air to be discharged. Various Steps Involved In Rotor Machining:-

SHAFT MACHINING:It involves finishing of shaft by machining it with a central lathe machine. It is done in accordance to the engineering drawing design. Special care is taken t o maintain the tolerance level. SLOTTING:Two types of machines do slotting, air cooled and liquid cooled. Slotting is don e diametrically. First the shaft is made to rest on two horizontal plates and is firmly attached to them with the help of chains which exerts load and with the help of jack so that it handles the vibrations produced during the slotting proc ess. Now the centre is marked and slotting is done. After slotting is done through on e side the shaft is rotated to the diametrically opposite end of the slotted por tion and then again slotting of that portion is done. It is done in diametricall y opposite ends so as to prevent bristling of slot due to mechanical vibrations. ROTOR WINDING :Rotor winding involves coiling of rotor. It is a two pole rotor. Rotor coils are made of pure copper + 0.2% silver, which has high tensile as wel l as temperature bearing properties. The coil doesnt deform even at high temperat ures as on adding silver the thermal stresses are eliminated. Rotor winding is a lso known as field winding which is wound in longitudinal slots in rotor.

ROTOR SLOT WEDGES :To protect the rotor windings against the effects of centrifugal forces, the win dings are secured in slots with wedges. Slot wedges are made of copper-nickel-silicon alloy featuring high temperature r esistance and high strength.

There is retaining ring, which protects the rotor from the impact of centrifugal force on end windings. Comprehensive tests such as ultrasonic examination and liquid penetration examin ation are carried out in the coils. To ensure low contact resistance, retaining rings are coated with nickel, alumin um and silver by three step flame-spraying process. ROTOR WINDING:-

The winding consist of several coils inserted into the slots and the series conn ected such that two coils group to form one pole. Each coil consist of several s eries connected turns each of which consist of two half turns connected by brazi ng 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 nom ex filter are used for slot insulation. The slot wedges are made up of high electrical conductivity material and thus ac t 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 tr ies to lift the winding out of slots, they are contained by wedges. Construction of field windings:The field winding consists of several series connected coils into the longitudin al slots of body. The coils are wound so that two poles are obtained. The solid conductors have a rectangular cross-section. These coils are formed arranging together the 14 no. of strips which makes a hal f of the coil which means that total 28 strips are used to make single coil of t he field winding. Depending upon the type of cooling there are 8 solid and 6 hollow strips in each half of the coil. Let us understand it with help of the flow chart: Coils placed together. Then Teflon insulation is done on them. A total of 13 layers are wrapped. Then epoxy glass tape is wrapped around. A card board of paper thickness is placed to keep the Coils separated. Then a varnish of 7556 is wrapped on it. Then kept free heating of about 6 hrs is done. Then a free heating of about 1.5 hr is done at low pressure of about 30 kg and 1 15*c temperature. Then for 45 minutes it is heated at temperature of about 130*c and pressure is i ncreased to 200 kg. Then keeping the pressure constant the temperature is raised to around 160*c and

coils are heated for around 3 hrs. Then the coils are removed off the pressure gradually and cooled by spraying wat er so now the temperature reaches 60*c then left to cool slowly and the coils ar e ready to be wedged in the slots. Then the coils placed in the slots and tighten up to prevent the loosening by ti ghtening rings. There are 7 turns per pole per pitch and rotor of 210 MW is ready to test. There is a slight difference in formation of coils 500 MW turbo-generators. In those generators the coils are arranged in the following manner. Firstly they alternate hollow and solid conductors. There are two solid conductors for every hollow strip and they are marked as A---- Which has 7 conductors. B---G where they have 9 conductors each coil. They are transposed by 540* as it removes air gap and improves cross over insula tion. It increases mechanical strength and help in producing equal E.M.F across all th e conductors. The insulation is molding mica mite. Testing involving the coils are thermal shock testing hot and cold. This testing is done to check the strength of brazing so that there is no water leakage and as a result it can bear thermal stresses easily. Nitrogen test is also performed for cleaning and leakage purposes and finally im pregnating it through vacuum impregnation technique. The vacuum impregnation technique is the latest technique to insulate the windin gs of stator and not used in rotors of any of the generators being used in the p ower plants nowadays. The process above is discussed is also known as transposition, which involves th e bending of the strips used in forming the coil of either rotor or stator. Conductor material:The conductors are made up of copper with silver content of approx. 0.1%. As com pared to electrolytic copper silver alloyed copper features high strength proper ties at high temperature so that coil deformations due to thermal stresses are e liminated. 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 pat h 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.

ROTOR RETAINING RINGS

The centrifugal forces of the end windings are contained by piece rotor retainin g rings. Retaining rings are made up of non-magnetic high strength steel in orde r to reduce the stray losses. Ring so inserted is shrunk on the rotor is an over hang position. The retaining ring is secured in the axial position by snap ring s. 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 o verhangs the end winding without contact on the rotor shaft. This ensures unobst ructed shaft deflection at end windings. The shrunk on hub on the end of the ret aining ring serves to reinforce the retaining ring and serves the end winding in the axial direction. At the same time, a snap ring is provided against axial di splacement of retaining ring. 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 blades of fan hav e threaded roots for screwed into the rotor shaft. Blades are drop forged from a luminum alloy. Threaded root fastenings permit angle to be changed. Each blade i s screwed at its root with a threaded pin.

BEARINGS The turbo generators are provided with pressure lubricated self aligning type be aring to ensure higher mechanical stability and reduced vibration in operation. The bearings are provided with suitable temperature element to monitor bearing m etal temperature in operation. The temperature of each bearing monitored with two RTDs (resistance thermo detect or) embedded in the bearing sleeve such that the measuring point is located dire ctly below Babbitt. 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 f rame.

FIELD CURRENT LEAD IN SHAFT BASE Leads are run in axial direction from the radial bolt of the exciter coupling. T hey consist of low semi-circular conductors insulated from each other and from t he shaft by a tube. The field current leads are coupled with exciter leads through a multi contact p lug in which allows unobstructed thermal expansion of field current. ROTOR ASSEMBLY:Rotor winding assembly and rotor assembly and rotor assembly like rotor retainin

g ring fitting. All these four assemblies are carried out in a ROTOR ASSEMBLY SE CTION present in BAY-1. This section is also in a dust-proof enclosure with no. of rotators, rotor bars laying facilities and MI heating and mounting of retaini ng rings. MACHINE SECTION:This section is present in BAY-2 (Turbo- Generators and Heavy Motors). This sect ion is equipped with large size CNC and conventional machine tools such as Lath es and Vertical Boring, Horizontal Boring machine, Rotor slot milling and Radi al drilling machines for machining stator body, rotor shaft End shields, Bearing etc for Turbo-generators. Same section is present in Bay-3 (Medium size motor s) equipped with Medium size machine tools for machining components for medium size AC and DC machines and smaller components of Turbo-generators and Hydro ge nerators .

VENTILLATION 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 ro tor is designed for radial ventilation by stem. The end stator is packets and co re clamping and is intensively cooled through special ventilation system. Design of special ventilation is to ensure almost uniform temperature of rotor winding s and stator core. COOLING SYSTEM STATOR COOLING SYSTEM The stator winding is cooled by distillate water which is fed from one end of th e machine by Teflon tube and flows through the upper bar and returns back throug h the lower bar of a slot. Turbo generator requires water cooling arrangement ov er and above the usual hydrogen cooling arrangement. The stator is cooled in thi s system by circulating demineralized water trough hollow conductors. The coolin g 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 sel ected. Generator is to be loaded within a very short period. If the specific r esistance of cooling DM water goes beyond preset value. The system is designed t o maintain a constant rate of cooling water flow through the stator winding at a nominal inlet with temperature of 40 degree centigrade, the cooling water is ag ain 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 i n turn cooled by Clarified water taken from clarified water header. ROTOR COOLING SYSTEM

The rotor is cooled by means of gap pickup cooling, where the hydrogen gas in th e air gap is sucked through the scoops on the rotor and is directed to flow alon g 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 oth er side of the rotor coil to the hot zone of the rotor, Due to the rotation of t he rotor, a positive section as well as discharge is created due to which a cert ain quantity of a gas flows and cools the rotor. The method of cooling gives uni form distribution of temperature. Also this method has an inherent of eliminatin g the deformation of copper due to varying temperature.

HYDROGEN COOLING SYSTEM Hydrogen is used as a cooling medium in large capacity generators in views of hi ghest carrying capacity and low density. Also in order to prevent used hydrogen from generators, casing and sealing system is used to provide oil sealing. The s ystem is capable of performing following system Filing in and purging of hydrogen safely without bringing in contact with air. Maintaining the gas pressure inside the machine at desired value at all the time s. Providing indication to the operator about the condition of the gas inside the m achine I e the pressure, temperature and purity. Continuous circulation of gas inside the machine through a drier in order to rem ove any water vapors that may be present in it Indication of liquid level in the generator and alarm in case of high level. GENERATOR SEALING SYSTEM Seals are employed to prevent the leakage of hydrogen from the stator at the poi nt 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.

BLK-I EXCITATION SYSTEM:EXCITER:EXCITER ROTOR The basic use of given exciter system is to produce necessary DC for turbo gener ator system. Principal behind this is that PMG is mounted on the common shaft wh ich 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 int o 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 e xciter is that is automatically divides the magnitude of current to be circulate d in rotor circuit. This happens with the help of AVR regulator which means auto matic 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.

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 bridges for rectifying AC volt age induced to armature to DC voltage. The pilot exciter is a PMG (permanent mag net generator). The PMG is also an AC machine with stationery armature and rotat ing 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 pe rmanent magnet rotor of pilot exciter. The shaft is rigidly coupled to generator rotor and exciter rotors are than supported on these bearings.

BAY IV (SMALL AND MISCELLANEOUS COMPONENTS) Facilities available in the various sections are as follows:MACHINE SECTION:The machine section of Bay-4 is equipped with small and medium size CNC & conven tional machine tools like centre lathes, milling, radial drilling, cylindrical g rinding, slotting, copy turning lathe, internal grinding and surface grinding ma chines. Small-size and miscellaneous components for Turbo-generators, Hydro gene rators and Motors are machined in this section. POLE COIL SECTION COILING SECTION

This section is equipped with baking oven , pneumatic shearing machines , semi-a utomatic winding machines , pole straightening installations , electric furnace for bright annealing of copper , tinning installation and hydraulic press (800 Ton capacity ) for manufacturing Pole Coils of DC motors , AC synchronous moto rs and hydro generators . Pole assembly is also carried out in this section. Manufacturing of coils (hydro generators) taken in this section. German copper c

oils are initially in the form of rolls. These rolls are then undergoes followin g processes to change into copper coils which are then mounted with poles1. ANNEALING PROCESS:-

This is the process of hardening or softening any metal. Initially copper rolls are hard & if it undergoes annealing then it may breaks s o firstly to make it soft so that it can easily change to winding. This process is carried out in the annealing furnace.

WINDING PROCESS:This process undergo following steps:Take out the softened copper rolls for pole coil winding. Winding is done with the help of change plate & winding template so working dimensions of change plate & winding template with respect to tool ing. Adjust & set the winding machine as per the product standards using hange plate & winding template. Ensure parallelity of winding template with ect to machine platform. Maintain height of winding template with platform. the coil in anticlockwise direction. NOTE:The joint in the copper coil shall be located in the straight part of longer sid e. If required heating by gas torch of copper profile at corner zone at temperature between 100-150 degree centigrade is allowed. This is to make easier bending.

ensure major draw gear rack, c resp Wind

2.

BRAZING:-

Braze the joint with brazing alloy Ag40Cd. Remove the coil with machine with 2 to 3 turns extra than the actual number of t urns for preparation of end-half turns. 3. Carry out bright annealing of the coil. Take out the coil from the oven after annealing.

4.

PRESSING:Pressing of coil is done by hydraulic pressure of 800 tons.

This process is carried out in order to remove wrinkles from the coil. This process is carried out after every process. In this process, set the coil o n the mandrel for pressing then slide the coil under press and press the coil. Take out the coil from press. 5. FIXING:Fix the accessory on the stretching machine. Put the coil on the stretching machine& pull the coil to the drawing dimensions. Dress the conductors along periphery & take out the coil. Check window dimensions as per drawing. 6. SEPARATION:-

Remove the buckling of each coil manually. Grind the bulging of the copper at place of binding (inner side) with pneumatic grinder. Check the thickness of the profiled copper with the gauge. Grinding shall be uni form & of smooth finish. Round of sharp edges. ** Again press the coil as in pt.5 & take out the coil from the press. 7. PICKLING:Send the coil for pickling to block 4 & check the quality of pickling. Press the coil again after pickling then remove pressure and take out the coil. 8. Prepare end half turn as per drawing with template.

9. Braze item 2 & 3 corresponding to the variant with end half turn with br azing alloy Ag 40 Cd. Remove extra material, clean and check with gauge. Adjust the end half turn with top & bottom turn of coil braze the joint. Remove extra material and check thickness of the gauge. Check the distance from center axis of pole coil as per drawing. 10. FINISHING:-

Hang the coil on stand and separate out turns Remove black spots, burrs the sharp edges and clean the coil turns with cotton d ipped in thinner. Press the coil again and check the height of the coil under press to check dimen sions as per drawing.

11. 12.

Take out the coil from the press and send for insulation. INSULATION:-

Hang the coil on stand and separate out the turn. Clean each turn with cotton dipped in thinner. Apply Epoxy varnish on both sides of each turn with brush uniformly all over the leaving top & bottom turn. Cut strips of Nomax paper as per contour of coil with technological allowance 3 to 5 mm on either side. Stick two layers of Nomax strips between each turn. Coat varnish layer between two layers of Nomax also. Let the excess varnish to flow out some time 13. BAKING AND PRESSING OF COIL:Place the coil on mandrel putting technological washer at top & bottom of the co il. Heat the coil by DC up to 100 +/-5o C , and maintain for 30 to 40 minutes. Switch off the supply and elongate the coil and tight the pressing blocks from s ides. Start heating coil again and raise temperature gradually in steps up to 130 +/5o C , with in 10 +/- 10 minutes. Apply 110 tones pressure and maintain for 20 to 30 minutes. Then after every hal f an hour, increases the pressure and temperature according to product requireme nt. Stop heating and then allow cooling the coil under pressure below 50o C, and tak ing out the coil from the press. 14. CLEANING AND DRYING:Clean outer and inner surface of projected insulation by means of shop made scru bber. Flow dry compressed air after cleaning. Check height and window dimensions as per drawing. Check no gap between the turns. Test the coil from inter turn test at 116 volts AC at a pressure of 480 tons in 5 minutes. 15. Coat the coil with two layers of epoxy red gel.

TURBO ROTOR COIL SECTION:This section is equipped with copper straightening and cutting machines, edge be nding machines, installation for forming and brazing, 10-block hydraulic press a nd installation for insulation filling. Rotor coils for water cooled generators (210 /235 MW) are manufactured in this section.

IMPREGNATION SECTION:This section is equipped with electric drying ovens, Air drying booths, Bath for armature / rotor impregnation. Rotors / armatures of AC and DC motors are impre gnated in this section.

BABBITING SECTION:This section is equipped with alkaline degreasing baths, hot and cold rinsing ba ths, pickling baths, tinning bath, and electric furnaces and centrifugal Shot Blasting babbitting machines, Babbitting of bearing liners for Turbo generators, Turbin es, Hydro generators, AC motors and DC motors is carried out in this section. TEST STANDS:Turbo-generators Test Bed -The Test Bed for Turbo-generators and Heavy motors is equipped with one no. 6 MW drive motor and a test pit for carrying out testin g of Turbo-generators and Heavy motors. Open circuit, short circuit, temperature rise, hydraulic and hydrogen leakage test etc., are carried out here for Turbogenerators. AC motors up to 11 MVA capacity and DC machines up to 5000 amps and 850 volt can also be tested. Two DC drive motors of 2200 KW and one of 1500 KW a re available for type testing of motors. Data logging equipment is also availabl e.

LARGE SIZE TURBO GENERATOR TEST STAND (LSTG):It is equipped with a 12 MW drive motor and two number test pits. Open circuit ,short circuit , sudden short circuit , temperature rise , hydraulic & hydro gen leakage tests are carried out here Large size Turbo-generators. This test b ed can presently test Tgs of unit capacity up to 500 MW. With certain addition i n facilities (Higher capacity Drive motor and EOT cranes and modification in con trols and auxiliary systems), Turbo-generators of unit size up to1000 MW can be tested.

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.

Testing of stator frame involves two types of testing:

HYDRAULIC TESTING AND PNEUMATIC TESTING Hydraulic testing involves in empty stator frame with attached end shields and t erminal box is subjected to a hydraulic test at 10 bar to ensure that it will be capable of withstanding maximum explosion pressure. The pneumatic testing involves filling of hydrogen in the sealed stator frame an d then soap water is used to check the leakage of welding.

CONTENTS1. 2. 3. 4. 5. 6. I. II. III. a) 1) 2) 3) b) 1) IV. V. a) VI. VII. VIII. IX. a) b) INTRODUCTION. BHEL A Brief Profile. BHEL An Overview HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP). Repair / Reconditioning Of Electrical Machines ELECTRICAL MACHINES (BLOCK 1) TURBO-GENERATOR. LARGE SIZE TURBO-GENERATOR. COMPONENTS OF TURBO-GENERATOR. STATOR STATOR CORE. STATOR WINDING. END COVERS. ROTOR STEPS IN ROTOR MACHINING. VENTILLATION AND COOLING SYSTEMS. EXCITATION SYSTEM. EXCITER. BAY-4 (SMALL AND MISCALLANEOUS COMPONENTS) TEST STANDS. LSTG TEST STANDS. TESTING. HELIUM LEAK TESTS HYDROGEN TESTING AND PNEUMATIC TESTING.

CONCLUSION The Vocational training at BHEL Hardwar helped me in improving my practical know ledge and awareness regarding Turbo Generator to a large extent. Here I came to know about the technology and material used in manufacturing of t urbo generators. Besides this, I also visualized the parts involved or equipment s used in the power generation.

Here I learnt about how the electrical equipments are being manufactured and how they tackle the various problems under different circumstances. At least I coul d say that the training at BHEL Hardwar is great experience for me and it really helped me in making or developing my knowledge about turbo generator and other equipment used in power generation.

REFERENCES 1. 2. Material provided by the training Incharge. Internet